Customer magazine by Putzmeister Concrete Pumps GmbH 75 ...

Customer magazine by Putzmeister Concrete Pumps GmbH 75
Frankfurt's OpernTurm is
growing with concrete pumps
and a "climbing boom"
French pumping service
with modern machine fleet and
additional business areas
Evenly pumped with EPS – air-entrained
concrete for avalanche protection PM
4114 GB

Content
Foreword
Current economic crisis an opportunity
Title story
Frankfurt's OpernTurm is growing
with concrete pumps and a "climbing boom"
Background
Not seasick in the slightest
On site
French pumping service with
modern machine fleet and additional business areas
Pumps used on historical soil
Rotor pumps free-flowing cement screed –
which can be walked on after 1 hour
Evenly pumped with EPS –
air-entrained concrete for avalanche protection
BSA with crawler track for the pile foundation
Concrete pumps on target
Practical tip
Too much pull?
Training
Intensive training on the "real" model
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Imprint
■ Editor:
Putzmeister Concrete Pumps GmbH,
Max-Eyth-Straße 10,
72631 Aichtal / Germany
■ Editorial department:
Jürgen Kronenberg,
Layout and graphics:
Friedrich Pippich,
Putzmeister Concrete Pumps GmbH,
Max-Eyth-Straße 10,
72631 Aichtal / Germany
■ Print: Druckerei Mack,
Siemensstraße 15,
71101 Schönaich / Germany
Current
economic crisis
an opportunity
For months now, the global financial crisis
has been shaking the foundations of the
international banking and financial system.
The precarious situation that many credit
institutions have found themselves in has
led to a restrictive financing policy felt by
our clients as well as ourselves.
The impact of the financial crisis has also
affected the real economy. The construction
industry is particularly affected, and has
had to record weak downturns, in particular
in the leading industrial nations. The recession
in the USA and other important
markets has not left our business untouched,
and has led to significant adjustments
in the organisation worldwide in line
with market conditions.
In addition to the negative economic development,
2008 has been shaped by our
Chinese competitors settling directly in
Europe. This will enable us to excel at new
technologies and prove our superiority in
terms of technology and service in a direct
comparison.
With the realisation of the global region concept,
Putzmeister is well positioned to take
on the new challenges: by means of forced
implementation of the global region concept
for sales and service, we are achieving an
even greater proximity to the global markets
and our customers. The global production
concept enables an optimised production
process that is based on the requirements of
the relevant market. The global logistics
concept acts as the third pillar in coordinating
the global production concept.
Without doubt, the current situation requires
even greater effort from all of us. We will
only succeed in traversing new paths if
together our employees, partners and customers
all revise their thinking. To achieve
this we have to move together even more
closely than in the past; together we will
master the new situation.
Foreword
All in all, we should not see the current economic
crisis as a threat, but as an opportunity.
Potential regarding new markets and
technologies are frequently not used to the
optimum in times of economic prosperity.
We are now being offered the opportunity to
direct greater attention to these areas in
order to emerge stronger from the current
crisis – even if this may take us some time.
I wish all of you and your families a Merry
Christmas and a Happy New Year.
Felix Selinger, Dipl.-Ing.
Managing Director of
Putzmeister Concrete Pumps GmbH
PM 4114 GB 3
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Title story
Frankfurt's OpernTurm is growing with
concrete pumps and a "climbing boom"
Ed. Züblin AG is currently erecting an imposing high-rise project, the OpernTurm, in the
centre of Frankfurt am Main at a breathtaking speed. Including its base plate, around
55,000 m 3 of concrete will be placed in the 170 m tower. The main players in the speedy
construction progress are, among others, Europe's largest truck-mounted concrete
pump M 63-5, a stationary high pressure concrete pump BSA 2109 as well as a stationary
boom MX-32-4, on newly developed tubular columns with a climbing system.
The new construction of tower building and
podium in front is located precisely opposite
Frankfurt's Alte Oper, which is steeped in
tradition, and will, once completed, blend
harmoniously into the surrounding architecture.
In the three basement floors, the
OpernTurm has 580 car parking spaces, and
approximately 67,000 m 2 office and business
space is rented over the 42 upper
floors. The project developer is the American
estate agency Tishman Speyer, which has
already formed a striking image with the
construction of the Frankfurt MesseTurm in
the metropolis on the River Main. As the
main contractor, Ed. Züblin AG is in charge
of turnkey-ready construction work. Construction
began in summer 2007 and is
expected to be complete by the end of 2009.
Massive base plate concreted with
5,660 m 3 in 72 hours
The order for concrete delivery, both for the
base plate and for construction of the building
itself, with 46 floors, was given to the
concrete pumping service "Die Pumas".
After extensive foundation work by Ed.
Züblin Spezialtiefbau GmbH (in consortium),
three truck-mounted concrete pumps from
the pumping service situated in Lorsch with
42, 52 and 63 metre booms took on the task
of concrete delivery for the base plate with a
thickness of 3.0 – 4.5 m in July 2007. Due to
the highly restricted space available, setting
up the large boom concrete pump was far
After 72 hours, the three truck-mounted concrete pumps have finished concreting the huge base plate, which is up to 4.5 m thick
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from easy: while there was space for the M
42-5 and M 63-5 with one-side support on a
makeshift ramp or on the very busy Bockenheimer
Landstrasse, the third machine had
to be set up on a specially-erected heavyload
frame. Three consecutive days and
nights were allocated for installing the
5,660 m 3 concrete (strength class C 30/35).
The Putzmeister M 63-5, the largest truckmounted
concrete pump in Europe, alone
delivered 2,000 m 3 of the total volume within
24 hours without any problems. In consideration
of performances at the neighbouring
Alte Oper, a 20-hour break from
concreting operations, which lasted several
days, was accepted. It was thanks to finelybalanced
concreting logistics that concrete
was transported by truck mixers through
the heavy inner-city traffic without any
obstacles.
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(Fig. Die Pumas)
The M 63-5 works with one-side support from the roadside (Fig. Die Pumas)
A small ramp is enough to set up the M 42-5 (Fig. Die Pumas)
Title story
PM 4114 GB 5
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Titelstory Title story
The concrete pumping service also has
stationary booms and pumps for large
projects
In addition to a large fleet of truck-mounted
concrete pumps (33 machines), the pumping
service "Die Pumas" also has five stationary
concrete pumps and seven stationary booms.
This leaves the company in the best possible
position to take on concrete delivery tasks
for demanding high-rise projects. At Frankfurt's
OpernTurm, "Die Pumas" are using
for the first time the new Putzmeister tubular
column system RS 850 with a simplified,
automatic climbing system that carries the
stationary boom with a reach of 32 metre.
Central constructional elements of the
OpernTurm are two building cores, which
will, when the building is complete, accommodate
the stair wells, lift shafts and supply
lines. During the building phase, the two
cores are always two to three stories ahead
of the floors. Both the two cores and the
floors are made of concrete of strenght class
"Die Pumas" associate Ingo Melzer
C50/60 with a maximum grain size of
16 mm. The concrete batches, delivered
from three mixing plants, are regularly
monitored on the construction site by a
laboratory.
Concrete placing boom stands
freely 16 m high on the tubular
column without lateral guides
During construction of the OpernTurm, the
stationary boom climbs upwards, in line
with construction progress, not inside one
of the building shafts but between the two
cores, through holes in the floor. A tubular
column and boom were installed after the
third floor was completed, i.e. at the height
of level "0" (ground floor). Since then, the
concrete placing boom has stood freely, without
ballast, on a tubular column 16 m above
the last floor guide. Due to its higher position,
the boom not only reaches every point
of the floors, each of which are 1,800 m 2 , but
also the formworks of the building cores,
which are three levels higher. The stationary
boom is connected to the stationary concrete
pump by means of an approximately
80 m long ground line (DN 125). Later on, as
the building height increased, the ground
line was continued as a riser up to 170 m.
Monitoring the concrete batches on the
construction site
Compact reinforcement (Fig. Tishman Speyer/Photographer: Klaus Helbig) The BSA 2109 H D is connected to the 170 m hi
delivery line
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The MX boom stands freely and without
ballast on the tubular column, 16 m high
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gh riser by means of an 80 m long horizontal
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New tubular column system automates
the climbing of concrete placing booms
The boom tubular column is held by four
lightweight floor corner brackets. Each
weighing approximately 35 kg, these guides
can comfortably be carried to the next but
one floor after the climbing procedure –
heavy floor frames are not an issue with this
system. In the Putzmeister RS 850 tubular
column system, the climbing cylinders and
locating bolts that are otherwise customary
are replaced by integrated extending feet
and the climbing system that is secured to
the tubular column and also rises. With the
new tubular column system, the delivery
line is also no longer guided sideways along
the column but integrated in the tubular
column. When the floor is broken through,
therefore, only one square opening is required.
Let the placing boom climb one storey,
set up the formwork, position reinforcement,
concrete and strip the formwork after
12 hours – on average, one storey is completed
every four days.
Title story
From a higher position, the PM stationary boom also distributes the concrete to
hard-to-reach parts of the ceiling formwork
Easy-to-move floor guides keep the
boom tubular column laterally fixed
PM 4114 GB 7
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Title story
The RS 850 system –
well thought out right down
to the last detail
New tubular column
The RS 850 tubular column system comes
with 3 m, 6 m or 9 m columns as standard,
with standard pipeline lengths. Different
tubular columns for setting up the boom
pedestal and arm assembly are not required.
The double M tubular column profile
requires only one simple, square cut-out
(1 m x 1 m) in the floors. When an adapter
is used, existing booms can continue to be
used with the RS 850 tubular column.
Automatic climbing procedure
The climbing system integrated in the tubular
column profile allows automatic climbing
in the building. Once the climbing procedure
is complete, the climbing cylinder is drawn
upwards along the climbing bar, using a
cable winch.
Simple column connection
Instead of the procedure common up until
now, in which the tubular columns had to be
laboriously screwed together, re-usable pins
are now used in the RS 850 system. They
can be simply inserted by hand and secured.
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In order to place the average of 100 – 120 m 3
concrete in the ceiling formworks, the concrete
workers need around three hours. To
concrete a core (30 – 50 m 3 ), one and a half
hours. The stationary concrete pump at the
base of the OpernTurm is operated by
Matheo Placido, one of the most experienced
"PUMA" machine operators. On top of the
formwork, a specially-trained construction
site employee controls the MX stationary
boom by radio remote control. The two
machine operators stay in contact by walkietalkies
so that the output can be adjusted
immediately. The boom and tubular column
climbing process, which is largely automated,
is also controlled by site workers. The
climbing procedure from one storey to
another, including placing the corner brackets,
takes approximately 1.5 hours.
Concrete is delivered right up to the top
level by a ZX pipeline that is around 250 m
long in total. This version is permitted for
use with pressures up to 130 bar. In fact, the
Putzmeister BSA 2109 H D in rod side operation
at the Frankfurt OpernTurm "only"
requires around 90 bar concrete pressure at
delivery rates of 35 – 40 m 3 /h.
Title story
When the floors are concreted, approximately 100 –120 m3 concrete is placed
within three hours, high above Frankfurt
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Machine operator Matheo Placido stays in contact with the boom operator up on the
floor by means of a two-way radio
Technical data of the BSA 2109 H D
Motor: 6-cylinder Deutz
Drive performance: 200 kW
Stroke: 2,100 mm
Diameter of delivery cylinder: 200 mm
Max. delivery pressure
(piston side): 91 bar
Max. delivery output
(piston side): 95 m3 /h
Transmission ratio
(piston side): i = 2.3
Max. delivery pressure
(rod side): 152 bar
Max. delivery output
(rod side): 57 m3 /h
Transmission ratio
(rod side): i = 3.8
PM 4114 GB 9
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Background
Not seasick
in the slightest
Since 22nd August 2008, the first M 70-5 large boom concrete pump has been on the
American continent. This was preceded by careful planning and routine processing by
PM dispatch, transfer to Bremerhaven on its own axis and a 3-week sea crossing.
Meanwhile, the second M 70-5 will soon be ready for delivery from Putzmeister in
Aichtal. It is also headed for an American concrete pumping service.
Putzmeister processes almost all transfers
of truck-mounted concrete pumps to customers
abroad with the support of two or three
renowned shipping companies. These transportation
companies have the best contacts
at the customs offices, liaison offices in the
countries of destination and, with their
experienced personnel, guarantee a reliable
transfer of machinery. For the M 70-5 transfer,
for instance, PM dispatch commissioned
the shipping company Alfons Köster & Co.
GmbH (headquarters in Hamburg). For noneveryday
shipping tasks, the large logistics
companies occasionally work together with
specialised partners.
This was also the case with the transfer of
the M 70-5 from the Aichtal Putzmeister
works to the roll-on / roll-off terminal (RoRo)
at Bremerhaven. This part of the journey was
overseen by the shipping company Gerber
Transfer und Logistik GmbH (Munich).
Some of their drivers are specially trained in
transporting heavy loads on roads. For one
thing was clear: a truck-mounted concrete
pump with 52-metre boom and a gross
weight of 48 t drives (and brakes) somewhat
differently to a machine weighing almost 80 t
with a 70-metre boom. Driver Hans Ott took
it all in his stride, however: with decades of
professional experience in heavy goods
vehicle traffic and gross vehicle weights of
over 300 t, he had done this more than
enough times in the past.
Different driving and braking behaviour
Since the M 70-5 was designed for the
American market, the machine required an
official certificate of exemption for the transfer
journey, on account of the special axle
configuration. This certificate specified not
only the course of the journey, but also offperiods
in which the journey had to be interrupted
(6.00 – 8.30 am and 3.30 – 6.00 pm).
An accompanying vehicle followed the 10axle
semi-trailer concrete pump at a distance
of 50 m. A police escort was not required.
The route took the vehicle directly north. The
only time that the semi-trailer truck had to
use non-motorway roads was when a motor-
way bridge section between Würzburg and
Fulda, prohibited for heavy goods vehicles
over 44 t, had to be avoided. Travelling via
Kassel and Hanover, the M 70-5 long-reach
boom pump reached the pier in Bremerhaven
after 816 km and 14 hours of travel time.
A 16,000 km sea journey
We asked the driver Hans Ott whether the
Kenworth C500B (10 x 6/4), which with
370 kW was not exactly "over motored", was
not too slow for a tractor unit. "No", was the
answer. "Even in the mountains around
Kassel, with their steep, drawn-out climbs,
we were still able to travel at at least 30 – 40
km/h." The experienced driver probably had
to adapt on the downward gradients: while
European manufacturers usually equip their
trucks in this weight class with eddycurrent
brakes or retarders as permanent
brakes as standard, the Kenworth still has
the traditional engine brake for stopping the
Specialist in unusual transportation:
driver Hans Ott
speed on longer downward gradients
("throttle valve" principle).
For shipping on the "Cepheus Leader", a
vehicle transporter 200 m in length, 32 m in
width and with a capacity of 62,600 GRT,
the concrete pump drove on board backwards
over a loading ramp. This showed
once more that the combination of tractor
truck and air-sprung semi-trailer is completely
manoeuvrable, even when the traffic
area is on different levels.
On the subsequent three-week sea voyage
on the "Cepheus Leader", the M 70-5 longreach
boom pump was left alone. Sailing
southwest, the huge transport ship crossed
the Atlantic and headed first for the east coast
of America and Florida's Jacksonville harbour.
The civilian section of the Jacksonville
harbour facility is the most important port
of transshipment for vehicles in the USA.
After a brief stopover, the journey continued
through the Caribbean, and in mid-August
the M 70-5, on board the transport ship,
passed through the almost 82 km long
Panama Canal, with its three lock installations.
After a total of 8,635 nautical miles
(approximately 16,000 km), on 22nd August
the largest truck-mounted concrete pump in
the world rolled off the ship in San Diego
harbour (California) on its own axis in a
wholly unspectacular manner – and without
any sign of sea sickness: Welcome to
America!
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On the loading ramp, the semi-trailer
concrete pump adapts to the different
levels (Fig. Köster)
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View of the Kenworth driver's cab
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The M 70-5 travels at speed even on rural roads
(Fig: L. Franke / Köster)
After a 16,000 km sea voyage, first arrival at San Diego harbour
Background
PM 4114 GB 11
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On site
French pumping service
with modern machine fleet
and additional business areas
In the small, northern French town of Hazebrouck, approximately 40 km south of Dunkirk, the construction company Eifrage TP
Nord (Wattignies/Lille) is currently building a rainwater storage basin with a capacity of 10,000 m 3 . Their customer is the municipality
of the township numbering 21,000 inhabitants. The basin, sunk 12 m deep, has a diameter of approximately 35 m and will
relieve the strain on the town's sewage system after heavy rainfall. It is only worthwhile to use truck-mounted concrete pumps
with a large working range and flexible boom technology here.
The order for pumping approximately 1,100
m 3 concrete for the basin wall, base plate
and eight columns that will later carry the
reservoir cover went to the concrete pump
operator Transports Samyn from Arques, 20
km away. The company's first Putzmeister
truck-mounted concrete pump M 47-5, only
a few months old, provides the best preconditions
for civil engineering, namely sufficient
reach and highly-flexible boom kinematics
in the 5-arm boom.
M 47-5 in civil engineering with
EBC boom damping
The machine stands, correctly supported,
directly in front of the concrete circle that
contains the rainwater storage basin, and
today will concrete the connection between
the base plate and the basin wall (52 m 3 ). To
do this, the machine operator, Bernard
Battel, has to drive the boom tip in an arc of
35 m diameter at a depth of 12 m. During
this process, the end hose is either within
the reinforcement or constantly approximately
20 cm above it. Since the M 47-5 is
equipped with EBC boom control, Mr. Battel
can switch on additional damping for the
placing boom using the radio remote control.
Machine operator Bernard Battel
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Wide, deep and across columns – the M 47 "Quintuplet" adjusts flexibly to
construction site conditions, even in this rainwater storage basin
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The M 47-5's flatbed offers ample space
for additional delivery pipes
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100 m delivery line on board – concrete
pressure can be limited with EPS
But the machine is also at home on construction
sites of very different scales. This
is clear from some specifications given by
customers. For instance, in France, the 35 t
4-axle vehicle (DB 4144) was loaded to 41 t
permissible gross weight and fitted with
additional brackets as well as support cradles
for further delivery pipes. It total,
Transports Samyn's M 47-5 can now carry
up to 100 m pipelines (DN 100) on board.
The computer-aided electronic pump control
stands the machine operator in good stead
On site
when ensuring that concrete pressure in the
delivery line installed on the ground does
not increase too much during pumping operations.
For the EPS system not only offers a
considerably quieter pumping process with
correspondingly lower fuel consumption in
comparison to conventional control systems,
it also allows concrete pressure to be limited.
To do this, the rotary selector on the
radio remote control can be used to specify
the maximum pressure required. This value
is also shown in the display and can be
changed at any time.
PM 4114 GB 13
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On site
Supplying concrete and other building
material for 25 years
The company Transports-Samyn has been in
existence for 25 years. It was founded by
Patrick Samyn, who quickly earned a good
reputation as a transportation company for
concrete and other building materials in
northern France, shortly afterwards setting
up his own concrete pumping service. In
2001, Damien Cousin took over the company,
including all employees. Meanwhile,
the workforce has grown to 47 persons,
including Cousin's wife Aurelie.
The vehicle fleet has almost doubled in the
past seven years. Alongside other trucks,
Samyn now has 15 truck mixers, 12 PUMI ®
truck mixer concrete pumps and 13 truckmounted
concrete pumps. The company is
distinguished by one special feature: some
of the Samyn truck mixers, both PUMI ® and
truck-mounted concrete pumps, can be rented
without machine operators, instead being
driven by internal personnel.
Mr. Cousin considers the main area of operation
for Transports Samyn to fall within a
radius of a roughly two-hour car journey
around the company headquarters in
Arques. For this reason, drivers frequently
do not return to company premises in the
evening, instead taking the concrete pumps
home with them. This saves both time and
fuel. The machines are then cleaned on the
premises of one of the concrete plants that
work with Transports Samyn.
Quick parts delivery
Damien Cousin has routine maintenance
work and repairs performed in his own,
well-equipped workshop. If wear parts are
required for the Putzmeister concrete
pumps that are not in stock in his own warehouse,
these can be supplied quickly. "Parts
transport from Putzmeister France's central
warehouse in southern Paris to us takes
only around three hours – I can live with
that", says Mr. Cousin in an interview. In
addition to the rapid-response customer
service, Mr. Cousin rates the constantly
expanding Putzmeister range of technical
innovations above all as positive, currently,
for instance, the "Follow Me" boom control
by movement of the end hose.
Damien Cousin, the "patron" of
Transports-Samyn
Safety taken seriously
The degree of seriousness with which the
issues of safety and employee training are
taken at Transports Samyn is exemplary.
For instance, before a new concrete pump
operator can take over his machine, an experienced
colleague accompanies him on
the construction site over a period of several
weeks. Thus, it is taught not just in principle
but also in practice how the PUMI ® or truckmounted
concrete pump is safely supported
or the required distance from power lines is
kept. Naturally, cleaning the delivery line
and pump is also taught "on the object".
Moreover, in Francois Gruwe, Transport
Samyn has an employee who, in addition to
his everyday work in the office and warehouse,
takes charge of complying with
safety-relevant aspects in the company, on
the vehicles and construction sites.
Mr. Cousin operates smaller construction sites with his truck mixer concrete pumps,
like the rotor PUMI ® 24.67 Q shown here
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Pumps used on historical soil
The plan is to open the extensive plot, with
its modern, landscaped swimming area by
the turn of 2008/2009. During the winter
months, the Bretton Woods area is primarily
visited by cross-country and downhill
skiers. At warmer times of the year, the
Mount Washington Hotel, above all the
rambling and well-manicured golf course, is
a focus for guests.
While the name Carroll, a small town in the
US state of New Hampshire that is home to
around 700 inhabitants, is hardly well
known, much has been written around the
world about the southeastern district of
Bretton Woods with its Mount Washington
Hotel, for some time. This is because the
imposing hotel, built in 1902, was the venue
for the Bretton Woods conference (1st –
23rd July 1944). The decisions made here
led a little later to the formation of the World
Bank and the International Monetary Fund
– institutions that, on the one hand, even
today play an important role in the international
economic system but on the other,
also face criticism from opponents of globalisation.
On site
The Mount Washington Hotel, which became known in 1944 as the Bretton Woods conference venue, is currently being expanded
into a wellness area. During the construction work concrete is delivered into the individual formwork sections by a Putzmeister
BSF 36.16 H.
M 36-4 carrying out concreting work in Bretton Woods (Fig. Brinkmann)
PM 4114 GB 15
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On site
Rotor pumps pourable cement screed –
which can be walked on after one hour
Many pump operators are presumably aware that rotor pumps can deliver not only concrete but also liquid screed. Liquid anhydritebased
screed (i.e. containing gypsum) is widespread, particularly in France, due to its easy workability for constructing floors in
residential and industrial construction. In the meantime, the cement screed suitable for external and damp areas has also been –
mark you: in pourable form – delivered by truck-mounted concrete pumps with rotor systems.
A typical construction site situation for this
is displayed by these photographs from a
Paris suburb. Here, the concrete pumping
service Inter Service Pompe (ISP) which
operates across the country is using a
Putzmeister pourable concrete pump BQF
28-4.80 from its fleet to cast the shared terrace
in the inner courtyard of a semidetached
house with pourable cement screed.
With its 4-arm, 28-metre boom, the dimensions
of the machine are more than sufficient
for this kind of job. A total of 16 m 3 material
is required for the outer area, which is
approximately 90 m 3 . The substructure consists
of a concrete ceiling of an underground
car park.
Once the 8 m 3 batch from the first truck
mixer has been pumped quickly into the
inner courtyard at the semidetached house
construction site, operations stall. The
second truck mixer is clearly in a traffic jam
and does not appear for another half an
hour. In the meantime, the concrete pump
operator has swung back the boom and
begun pumping the pourable cement screed
in a circle, with the end hose over his own
hopper. This is because he knows the mixture
breakdown, which, among other elements,
contains a maximum grain size of 8 mm,
300 kg/ m 3 cement and a setting accelerator:
although the material is nothing special
to look at (consistency of pea soup), it has
to be processed very quickly, as the screed
will set after only an hour, allowing the
ground to be walked on.
The Putzmeister BQF 28-4.80 is equipped
with a rotor pump. The delivery system is
largely the same as the rotor, as is known
from the rotor PUMI ® . With a delivery output
of 80 m 3 /h (max./theor.), the rotor unit
in the truck-mounted concrete pump is,
however, significantly more powerful than
that on the PUMI ® .
Looking over the new 2-storey building from the street – with the 28-metre boom,
the BQF rotor concrete pump has a considerable working range
16 PM 4114 GB
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If a truck mixer does not come and the concrete threatens to set,
only one thing helps: pumping in a circle (i.e. into your own hopper)
The machine does, however, have all the
benefits that characterise a rotor pump
■ very quiet in operation
■ continuous, interruption-free delivery
■ even the smallest concrete volumes can
be pumped
■ pump system and concrete hopper can
be emptied almost completely after use
– meaning that there is no concrete
residue to dispose of
■ easy to clean
Overview of screed types
On site
A basic distinction is drawn between
screeds based on cement and those
based on anhydrite, both of which are
available in different quality grades.
While traditional screed (bonded by
cement or gypsum [anhydrite]) does
not pump due to its stiff, thin consistency
but can only be delivered using
compressed air (Putzmeister Mixokret
system), liquid screed based on anhydrite
and cement is well pumpable and
easy to process. Due to its particularly
even pumping characteristics, screw
conveyor pumps, as well as rotor
pumps, are mainly used to deliver this
material.
But anhydrite liquid screed with gypsum
as a binding agent does not have
only benefits. For instance, this material
is not suitable for outside structural
elements (balconies, terraces, garages),
or rooms with high air humidity (bathrooms,
shower rooms, swimming pool
areas). Due to the relatively high water
content, floors made of anhydrite liquid
screed cannot be walked on or bear
load until considerably later than floors
constructed from traditional cement
screed.
Cement-bonded liquid screed is, therefore,
an alternative for floor construction
in outside or wet areas. It contains
Portland cement as the binding agent
and is laid floating or sliding, as with
synthetic resin cement screed (binding
agent: resin coated special cements).
PM 4114 GB 17
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39

On site
Evenly pumped with EPS – air-entrained
concrete for avalanche protection
Klosters is erecting an avalanche protection gallery at a height of 1,800 m in the
Swiss Canton of Graubünden. The standard EPS equipment for the stationary concrete
pump BSA 1003 D stands the machine operator in good stead when air-entrained concrete
is to be delivered, as this equipment can limit the maximum delivery pressure
precisely. Despite frequent concreting operations, the firm manages to avoid any disruption
to railway services on the Klosters-Davos route.
By creating a gallery on another section of
track, the Rhaetian Railway is eliminating a
possible source of danger that can, in some
Alpine regions, lead to repeated accidents
due to landslides and avalanches after heavy
precipitation. The construction site for protecting
the railway track is located only a
few kilometres north of the popular holiday
resorts of Davos and Klosters. The construction
costs are estimated at CHF 2.7 m.
(approx. EUR 1.8 m.).
In order to construct the 90 m long Seehorn
avalanche gallery (7 m wide, 8 m high) all
components will be concreted using a concrete
pump, and even the 61 double-sided
slanted concrete supports will be manufactured
on site. The gallery has a longitudinal
gradient of 2.5 % and, due to the small curve
radius, a transverse gradient of 6.4 %. Due to
the limited space available and the trains
running at 20-minute intervals, particular
care has to be taken with the logistics of the
construction site.
Air-entrained concrete prepared
homogeneously in the mixing trough
The construction site equipment directly
next to the railway track includes a small
concrete mixing and pump installation. The
pre-mixed gravel components (0 – 32 mm)
are delivered by truck and transferred to a
compulsory mixer with a tipping trough.
The exact quantities of cement, plasticising
admixture and air-entraining agent are
added in this mixer. With the air-entraining
agent, the construction site reaches a pore
volume of approximately 4.3 % in the concrete.
The tiny air voids are required in
order to create numerous small air chambers
in the cement paste, which provide space
into which the freezing water can expand at
winter temperatures. This increases the
A glimpse of how the construction site is set up: The tipping trough (right) in its vertical position transfers the gravel additives into a
compulsory mixer (covered with a sheet here), in which the aggregate is prepared with water, cement, plasticising admixture and airentraining
agent to form concrete. Underneath that is a double-shaft additional mixer, which transfers the concrete batches to the
hopper of the BSA 1003 D.
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component's frost resistance. After being
mixed for 90 seconds in the compulsory
mixer, the concrete and its additives are
intensively homogenised once again in a
double-shaft pre-mixing trough with a 3 m 3
volume, which transfers the concrete in
equal doses to the hopper of the BSA 1003 D.
Concrete pressure always under control
While delivering air-entrained concrete
using a rotor pump may be problem-free (a
maximum pressure of 25 bar may apply, depending
on the system), caution is necessary
when a piston pump such as the BSA
1003 D is used: for instance, at higher concrete
pressures (up to 80 bar is possible
with this pump type) the air voids in the
concrete are compressed and thus destroyed.
In consequence, the concrete would no
longer be frost resistant and the component
would have to be torn down again.
Putzmeister stationary concrete pumps have
clear advantages here, due to Ergonic ®
pump control (EPS): with EPS the maximum
pressure required can be set precisely. This
is practical not only for pumping concrete
with air voids, but also if the pipeline's wall
thickness (i.e. its compressive strength) is
unknown.
Over the course of the 62 concreting operations
between July and October 2008, the
BSA 1003 D delivered concrete outputs of
15 m 3 /h at pressures between 19 and 24
The work does not interfere with rail
traffic
41
bar. It manufactured foundations, guide
walls, back walls, supports and floors for the
gallery, concreting sections of 15 to 150 m 3 .
During this time, the length of the delivery
line (DN 125) reached up to 130 m. At two
points, the pipeline had to pass under the
railway embankment, in consideration of
the client's strict special requirements. In
total, the BSA 1003 D delivered 1,900 m 3
air-entrained concrete (C25/30, exposition
class: XF4) for the Seehorn avalanche gallery,
with 36-40 cm spread and a relatively
low W/C eq value of 0.42.
Information on the Rhaetian Railway
The Rhaetian Railway (RhB) is a narrowgauge
railway company in the Swiss
Canton Graubünden, founded in the year
43
On site
Gallery construction has the same longitudinal and transverse incline as the 61 concrete
columns on the valley side
Measuring device to determine the air
void contents
1888. The RhB has a rail network of total
384 km in length, with a track width of
1,000 mm, made up of eight regular
stretches of track and one motorail connection.
Every year, the Rhaetian Railway
transports 9.7 million passengers.
The RhB's rolling equipment includes 80
locomotives, 391 passenger carriages
and 743 goods wagons. With 1,270
employees, the company generates revenue
of approximately CHF 296 m.
(approx. EUR 197 m. (all figures from
2007). A significant part of the business
profit is spent on ensuring the safety and
on renovating routes, including the 582
bridges and 114 tunnels, as well as on
modernising the machine fleet. In summer
2008, the technically and scenically
spectacular RhB rail route between
Thusis and Tirano (Albula/Bernina) was
designated a UNESCO World Heritage
Site.
PM 4114 GB 19
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Practical tip
Too much
pull?
Pipe brackets on placing booms play a
"bearing role", since, on stationary
booms and truck-mounted concrete
pumps, they connect the delivery line to
the outrigger. But it is important to make
sure that pipe bracket clamping strips
are not fastened too tightly!
At Putzmeister, a pipe bracket design in
which delivery pipes are usually clasped
and held by a pipe clamp before and after
the coupling has been proving its worth for
years now. The bracket is made of a flexible
steel clamping strip and a steel pipe rest as
a counterpart. With this design, the actual
holding powers are deflected to the boom by
Stress distribution in the area of the
pipe bracket when the clamping strip is
very tight
means of a pipe holding pipe welded securely
to the pipe rest.
The trend seen in recent years towards
greater boom lengths, reduced material
thickness (in the interests of saving weight)
and, on average, ever greater concrete pressures
requires increased attention to be paid
A reduced tightening torque on the clamping strip relieves clamping strips, delivery
pipes and pipe brackets
to the way in which delivery pipes are secured.
This is because the clamping strip pivots
react highly sensitively if tightening torques
are too great. In extreme cases, this could
even cause strips to crack. This is added to
by the dynamic loads of the placing boom,
which lead to additional forces on the clamping
strips.
However, if the screw tightening torque is
too great, this will also have detrimental
effects on the wear and weight optimised
twin pipes. These double-walled delivery
pipes are now part of the original equipment
for most Putzmeister truck-mounted
concrete pumps and repeatedly baffle concrete
pump operators due to their longevity.
However wear-resistant twin pipes may be,
if the clamping strip is tightened too much,
cracks may appear in the inner pipe. Cracks
in twin pipes are usually harmless, however.
But if the inner pipe becomes so distorted
that gaps appear, the cracks will be eroded
at this point and increased wear will occur.
For this reason, Putzmeister recommends
reducing the screw tightening torque on
clamping strips in order to relieve the strain
on pipe brackets and delivery pipes. If the
tightening torque is reduced on the clamping
strip, the pipe is fixed significantly more
flexibly in its bracket than it was previously,
since minimal pipe movements in the bracket
can be made without any great resistance.
This prevents secondary bending and relieves
clamping strips, delivery pipes and pipe
brackets.
In practice, this means that tightening
torques can be lowered to 15 Nm when new
pipework is initially assembled (including
new clamping strips). If a torque wrench is
not available, the following procedure is
recommended:
1. Without increasing your effort, tighten
the clamping strip screws until the clamping
strip is resting against the pipe and you
feel increased resistance when you turn the
wrench.
2. To reach the required screw tightening
torque of approximately 15 Nm, turn the nut
on a free-moving thread one full turn
(360°). If the thread is stiff, 1.5 turns (540°)
are advisable.
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46

BSA with crawler track
for the pile foundation
In September, considerably earlier than planned, the Spezialtiefbau consortium (Ed.
Züblin AG and Bilfinger Berger AG) completed the contracted foundation work for the
future Rhine Gallery in Ludwigshafen. A significant amount of this rapid construction
progress was due to a Putzmeister concrete pump on a crawler track, which manufactured
hundreds of drilled piles using the screw conveyor in-situ concrete procedure
(SOB).
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Both on crawler trucks, the heavy augured pile device and the concrete pump
can also be used to their full extent "off road". A hose line creates the connection
between the two machines
The new shopping centre, which later will
have 120 retail outlets, is being built on a 10
hectare plot in Ludwigshafen, on the former
Winterhafen site, which was filled in in 1957.
To ensure that the planned Rhine Gallery
will stand on firm ground, its 400 m x 80 m
base plate is being erected on numerous
reinforced concrete pillars, which are placed
in a precise grid.
Before the 15.5 to 21 m deep holes are sunk,
any existing obstacles in the building
ground were eliminated by means of fragmentation
drilling. To manufacture the SOB
pillars, a heavy piling device was used to
screw a hollow stem auger in the prepared
building ground. Once the target depth was
reached, concrete was delivered under
pressure using the bore of the endless auger
in the hole. In this process, the drilling
apparatus pulled the auger upwards without
rotating it. Once the auger and the drilled
material accumulated on the surface had
been removed, a reinforcement cage was
shaken onto the freshly-concreted pillar.
The holes were filled with concrete by a
Putzmeister BSA 1412 D RF pump on a
crawler track. The machine is equipped with
an off-road chassis so that it can follow the
Practical tip
chain-driven, heavy piling device even on
unsecured terrain. The two machines were
connected by means of an approximately
22 m long hose line that was connected to
the auger on a pipeline with flexible
connection hoses (DN 125). Drive commands,
steering and operation of the concrete
pumps were performed via radio remote
control. The relatively high pump output
(max. 120 m 3 /h) was not required in continuous
operation when the drilled piles were
concreted, but was frequently beneficial
during the first phase of hole filling when
relatively large volumes of concrete had to
be installed quickly.
Meanwhile, many civil engineers prefer to
use self-driving construction site concrete
pumps to fill the drilled piles, and for good
reason. This is because, in contrast to truckmounted
concrete pumps, a crawler track
BSA does not have to be supported, and can
begin work on the next hole within a very
short period of time. In addition, when constructing
pile foundations, concreting with
this machine is much safer as it does not
require such precise coordination of movements
between the two machines: the danger
of the drilling apparatus suddenly pulling
on the end hose, and therefore on the placing
boom, is also excluded (result: the truckmounted
concrete pump tips over). And, in
comparison to concreting with a delivery
pipe, the placing output with a concrete
pump is considerably higher.
Of the 580 concrete piles, the Spezialtiefbau
consortium manufactured 510 (between 90
and 120 cm in diameter) out of screw conveyor
in situ concrete. The average daily output
was between 12 and 13 SOB pillars. The
remaining 70 piles are concreted in the
usual way with a delivery pipe. In total,
approximately 9,000 m 3 concrete (C25/30)
was required for the pillar foundations of
the Rhine Gallery.
The machine operator controls the selfdriving
concrete pump
PM 4114 GB 21
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On site
Concrete pumps on target
Since January 2008, an extensive building complex has been under construction
directly on the start and home stretches of the Nürburgring. During concreting operations,
it is good to observe the ever-changing Putzmeister truck-mounted concrete
pumps such as the popular models M 24-4 and M 36-4, the compact M 46-5 and M 52-5
or the imposing M 58-5 and M 62-6. With their 5 and 6-arm booms, the long-reach
boom pumps, which extend over walls, can reach even inconveniently-situated formwork
sections.
From the set-up site beyond the 350 m long wall, the PM long-reach boom pump M 62-6 can comfortably reach the formwork
sections for the new "world of adventure" at the Nürburgring
For around € 25.5 million, the carcass of a
"world of adventure" is being erected opposite
the grandstand on the legendary race
track in the Hocheifel region. Among other
elements, the project includes an underground
car park (700 parking spaces), a
"boulevard", on which automobile manufacturers
and accessory suppliers will give presentations,
an arena for 3,500 guests, an
"event hall" with capacity for 1,800 people
and the "Welcome Centre". The leisure time
facilities will be rounded off with a gocarting
track and a roller coaster. In addition,
a new, modern grandstand is to be built
with 5,000 covered seats as well as a "business
lounge" for 600 guests. The order for
the 350 m-long building complex has been
assigned to the Nürburgring consortium
(Ed. Züblin AG, Max Bögl Bauunternehmen
GmbH & Co.KG and Fritz Meyer GmbH).
Around 60,000 m 3 of ready-mixed concrete
will be delivered by the mixing plants of
KANN Beton GmbH & Co. KG, Beton Union
Rhein-Ahr GmbH & Co. KG as well as
CityMix GmbH for this major project. With
the truck-mounted concrete pumps used,
the supply association is able to rely on its
own fleet, to a certain extent. Thus, Beton
Union is once providing its 21-metre PUMI ®
and truck-mounted concrete pumps with 27,
28 and 34 metre booms, and KANN Beton a
24-metre PUMI ® , a M 24-4 and a M 36-4. In
addition, CityMix is ordering its M 36-4 as
well as the new M 46-5 to the Nürburgring.
If, however, greater horizontal reach and
boom flexibility is required, the long-reach
boom pumps M 52-5, M 58-5 and M 62-6
owned by BEKA Betonpumpen-Service
GmbH will be ordered to the construction
site.
Practically all of the machines are also consistently
in use for the construction of the
neighbouring "Congress & Motorsporthotel
Nürburgring". An additional 20,000 m 3 of
concrete will be delivered here. Work on the
new 4-star hotel began at almost the same
time as the laying of the foundation stone for
the "adventure world" along the start/home
stretches. On completion, the classy 160room
lodgings will also have a helipad and
direct access to the grandstand.
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This M 36-4 is concreting the base plate of the neighbouring
"Congress & Motorsporthotel Nürburgring"
Training for the 5th run of the long-distance championship at the Nürburgring
51 53
PM 4114 GB 23
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Attractive world
of motor racing
On site
Completed in 1927, the Nürburgring
with its 89 left and 85 right-hand
bends, inclines up to 27 % and a
length of almost 23 km was, until
1977, a regular venue for the Formula
1 Race – "Grand Prix of Germany".
After several serious accidents, however,
the track was made off-limits for
the Grand Prix sport. After its first
reconstruction (1983), with provision
for extensive safety measures, the
ring, surrounded by beautiful countryside,
has been used for motor
racing once more since 1984.
In the meantime, the legend of the
Nürburgring has become a brandname
product. More than 300 races,
leisure time, incentive and music
events are held here professionally
every year. The circuit includes both a
Nürburgring racing driver school and
a course in driver safety training.
Approximately two million people
attend the numerous events every
year, or take advantage of the leisure
facilities all around the famous race
track. Due to growing interest, the
offer has now been extended from the
coming year, for that is when the
"Leisure and business centre
Nürburgring 2009" project, costing a
total of € 215 million, is to be started
up.

Training
Intensive training
on the "real" model
With an attractive range of programs on
offer, the Putzmeister Academy has started
its training season 2008/2009. The
many courses available have different
areas of focus and are directed towards,
among others, concrete pump operators
with little practical work experience and
experienced machine operators who want
to refresh or enhance their knowledge, as
well as operations managers, fleet scedulers
and workshop managers.
Since the Putzmeister trainers not only
impart theory but also want to undertake
practical work with seminar participants
"on the real thing", Putzmeister has installed
two complete training pumps in the
training rooms. These are "real" truckmounted
concrete pumps without the truck
chassis, and are driven by an electric motor.
This kind of practical work on fully-functioning
models allows participants to carry out
all necessary set-up work, for instance, and
receive direct training in troubleshooting.
The two training concrete pumps are also
equipped with additional sensors. These
record all of the important data for concrete
pumping operations, such as main pump
high pressure, low pressure, charge pressure,
control pressure, accumulator pressure and
volumetric flow rate, as well as the pump
control system's electric control current.
This data is transmitted to a PC by means of
a CAN bus system. The computer visualises
the measured values obtained and presents
the information accurately in the form of
virtual pressure gauge displays. These displays
are shown to all seminar participants
in enlarged format as projected images. By
preparing the visualisation in a didactical
manner, the seminar leaders can illustrate
complex processes and dependencies in the
hydraulic systems of Putzmeister concrete
pumps.
In the meantime, practical modules both on
the training pumps and on the "right" truckmounted
concrete pumps have become an
integral part of any course for machine operators
and mechanics at the Putzmeister
Academy. For more information, call
+49 (0) 7127 599-586.
Putzmeister Concrete Pumps GmbH, Max-Eyth-Str. 10, 72631 Aichtal
PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458
One of the "real" concrete pumps with an image projection of all important parameters
– an example of practice-oriented training at the Putzmeister Academy
All rights and technical details subject to alteration · The illustrations show special mechanical equipment and snapshots in practice on construction sites, which do not always
correspond to the regulations of the Industrial Employers’ Liability Insurance Association · © 2008 by Putzmeister Concrete Pumps GmbH · Printed in Germany (40812Ma)
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