With DVD: The new 42-5 - Putzmeister

1
The magazine by Putzmeister Holding GmbH 81
With DVD:
The new 42-5
New runway for
Germany's largest
airport: Large boom
pumps concreted
taxiway bridge
New pumping record in
North India's Himalaya
New standards for
truck-mounted concrete
pumps: 42-5
New railway tunnel in
Vienna: Long distance
concrete delivery in the
Lainzer Tunnel
PM 4377 GB

Content
Content
2 4
Title story
Lainzer Tunnel in Vienna:
Concrete placed over 1400 m distance 4
The new 42-5
WELCOME
WELCOME
Revolutionary!
The next generation of the 42-5 8
On site
Airport Frankfurt am Main:
Large boom truck-mounted concrete pumps placing
concrete for taxiway bridges of the runway North East 14
Uttrakhand / North India:
BSA pumps Indian long distance record
of concrete placement! 20
4
Tunnel concreting in the
Lainzer Tunnel, Vienna
8
All new:
The next generation
of the 42-5
3 5
WELCOME
In October, we will be presenting
the new 42-5 in a
roadshow at the following
locations, with each show
taking place
from 11 a.m. to 5 p.m.
New pre-cast concrete plant for wind power systems:
Analysis of concrete mix with the rheometer 24
Tue 4th Oct.
Putzmeister Aichtal
50 Questions
What does Putzmeister do against wear and tear? 12
Putzmeister Solid Pumps
Wed 5th Oct.
Frankfurt Service Centre
Thu 6th Oct.
Essen Service Centre
Ship and offshore applications
Drill cuttings storage and pumping system
on Norwegian ships 26
In brief
Caution: Snappy ad! 28
M 52 approaching the Hoover Dam bypass bridge 29
Large project in Saudi Arabia:
King Abdullah Financial District 30
Telebelt reduces the costs of placing mass
concrete in Chinese shipyard 31
Photo credits 2
Imprint 3
14
Large concreting work
of taxiway bridges at
the airport Frankfurt
Photo credits:
Unless indicated otherwise, all illustrations are copyright
Putzmeister Holding GmbH.
18: Europe_topography_map_en, Wikimedia Commons,
licensed under CreativeCommons license bysa-3.0,
San Jose · 3, 28 - 35, 37: Die Pumas · 36:
Fraport AG · 39: Public Domain, SKopp · 47: India_
uttarakhand_locator_map, Wikimedia Commons,
licensed under CreativeCommons license by-sa-3.0,
PlaneMad/Wikipedia · 48: bhagirathi_river_map,
Wikimedia Commons, licensed under CreativeCommons
license by-sa-3.0, Fowler&Fowler · 49: nanda_
devi2, Wikimedia Commons, licensed under CreativeCommons
license by-sa-2.0, Michael Scalet · 53:
strabag_gelände_luftbild, www.offshore-basis.de
· 54: barrow_offshore_wind_turbines, Wikimedia
Commons, licensed under CreativeCommons license
by-sa-3.0, Andy Dingley · 55 - 57, 59 - 60: Putzmeister
Solid Pumps GmbH · 58: Valkyrie_by_Robert_Engels_(black_and_white).png,
Public Domain
· 64, 65: www.kingabdullahfinancialdistrict.com
Imprint:
Editor:
Putzmeister Holding GmbH
Max-Eyth-Str. 10
72631 Aichtal · Germany
Editorial department/Layout/DTP:
Petra Montag
Putzmeister Holding GmbH
Print:
Offizin Scheufele GmbH & Co. KG
Tränkestr. 17
70597 Stuttgart · Germany
Indian record in
long distance pump-
20ing of concrete!
All rights and technical amendments
reserved.
Although content is checked carefully,
we accept no liability for sites to
which links are given. The operators of
extern al websites are solely liable for
their content.
Some of the illustrations show special
machine variants and snapshots which
do not always comply with the regulations
of the Industrial Employers’ Liability
Insurance Association.
© by Putzmeister Holding GmbH 2011
Printed in Germany (41109)
Sat 8th Oct.
Hamburg Service Centre
Mon 10th Oct.
Berlin Service Centre
Wed 12th Oct.
Gera Service Centre
Fri 14th Oct.
Munich Service Centre
2 PM 4377 GB PM 4377 GB 3

Rubrik Title story
Title Rubrik story
Lainzer Tunnel in Vienna:
Concrete placed over 1400 m distance
The Lainzer Tunnel is a railway tunnel in
Vienna that is 12.8 km long and, from
December 2012, will connect the Westbahn
(west ern railway) with the Südbahn
(southern railway) and the Donauländebahn
railway. The purpose of this plan is
to increase the capacity of the east-west
transit system.
The tunnel starts at the Wien-Hadersdorf
station and runs below the Lainzer Tiergarten
to the west of Vienna, from Speising
close to the existing junction line
and, at its mouth, joins the Südbahn line
before Wien-Meidling station and the
Donauländebahn line in Altmannsdorf. It
is part of the Westbahn and the European
High-Speed Line be tween Paris – Budapest.
The LT 31 consortium (HOCHTIEF
Construction AG, Alpine Bau GmbH and
Beton- und Monierbau GmbH), under
the leadership of HOCHTIEF Construction
AG, was commis sioned by the ÖBB-
Infrastruktur Bau AG to construct a main
section of the Lainzer Tunnel.
To execute the inner lining in built-up
areas, from October 2008, the concrete
for separating the underground transport
traffic from the above-ground transport
traffic was pumped through a permanently
installed delivery line, measuring
be tween 300 m and 1400 m in length,
from the concrete mixing plant at the
construction site directly to the placement
site.
The concrete mixture was designed to
meet specific structural and pumping requirements
and was subject to continuous
monitoring from a concrete technology
perspective throughout the duration
of the construction project.
6
The interior construction of the tunnel
was performed using a watertight concrete
inner shell (d>=50 cm), with PP
fibres added to the concrete in order to
improve its resistance to fire. In addi tion,
the inner shell was designed with an
8 cm enlarged concrete covering of the
reinforcement (reinforcement proportion
of the tunnel lining is approx. 85 kg/m³
of concrete).
The formwork carriages for each segment
of the tunnel were 10 m in length,
result ing in an installation quantity of
approx. 150 m³ of concrete for the tunnel
lining of each concreting section and of
90 m³ for the base.
The interior work had already commenced
in parallel to the headwork, and
the concrete was fed via two vertical
starting shafts. It was therefore decided
at an early stage to supply the concrete
for the formwork carriages using a stationary
concreting facility – consisting of a
stationary concrete pump and a specially
designed delivery line. As a result of the
positive experience gained from the beginning,
this form of concreting logis tics
was maintained even after the headwork
was completed. In the construction phases
S and M, one delivery line each was
available for the base and the arch for
the concreting logistics. As a result, up
to four formwork carriages could be filled
with concrete in parallel. In this way,
concreting outputs of up to 500 m 3 per
day with reinforcement work running in
parallel could be achieved. This had the
positive effect that restrictions and obstructions
in the tunnel could be elim-
ÄÄFacts and figures
Total figures for the Lainzer Tunnel
Line length
12.8 km
Tunnel length
12.3 km
Total length of track reconstruction
and construction
25.3 km
Civil engineering works
• 7 approach shafts
• 4 entrances
• 28 emergency shafts
• 4 factory buildings
• 4 construction and reconstruction
of S-Bahn stations
• 6 street crossings
• 10 rail crossings
• 5 pedestrian and bicycle
crossings
• 2 river crossings
• 3 installation collectors
LT 31 Maxing construction section
Length
approx. 3,050 m
Overlying
6 – 26 m
Tunnel width
13.60 m
Tunnel height
12.56 m
Starting and hauling shafts
Depth
approx. 30 m
Length
approx. 24 m
Maximum width approx. 17 m
Minimum width approx. 10 m
7
t The separating film can be seen in front of the arch formwork carriage. It separates
the inner and outer shells of the tunnel. This separating film is used to secure the steel
reinforcement for the final concrete inner shell.
4 PM 4377 GB PM 4377 GB 5

Title story
Title story
8
composition table), had to meet the
requirements for a construction that is
dense (WDI), fire-resistant (BBG) and
self-compacting (SCC), and it also had
to represent an economically attractive
solution for the execution. From a structural
point of view, a grading curve with
an increased sand content (70 %) and
a reduced maximum particle size GK 16
mm round grain was selected. With a
binder content of 280 kg/m³ CEM I 42,5
R (C3A-free) and the addition of a type
I additive (AHWZ - Effective Additives
Prepared Hydraulically) of 170 kg/m³,
a fines content of over 540 kg/m³ was
prepared.
PP fibres with a short fibre length
(3 mm) were added in the dosage
describ ed in the table. Consistency tests
on the fresh concrete showed a diameter
of concrete flow of 58 cm with very good
fluidity and sufficient self-compaction.
Concrete composition WDI / BBG / SCC
Base material
Quantity
Cement CEM I 42,5R HS C3A-frei 280 kg/m 3
Fluamix C 170 kg/m 3
Chargeable binder 388 kg/m 3
Water in scc. with batch report 185 kg/m 3
LZF/LZ51 1)
LP 100
Stabilisator Strong
5.6 kg/m 3 / 1.24 % from cement amount
0.18 kg/m 3 / 0.04 % from cement amount
1.6 kg/m 3 / 0.36 % from cement amount
Fibes PM 3/15 2) 1.2 kg/m 3
Stone particles (dry) 1706
0/4 70 %
4/8 10 %
8/16 20 %
1) The LZF/LZ51 was apportioned in the ratio 70:30.
2) The fibres PM 3/15 were added to the forced mixer by hand.
In the next part of the construction project,
Putzmeister systems engineering
was also used for construction phases S
and W, with a total of six stationary concrete
pumps, delivery lines and functional
elements. This was not just because of
the design of stationary concrete pumping
technology which balances economical
and technical factors but also because
of the outstanding local-service
provided by the Austrian Putzmeister
dealer, Hans Eibinger GmbH. n
9
p A hose was branched off from the delivery line and fed the BSA 1408 E at the arch formwork carriage
inated by simultaneous reinforcement
and concrete transport. It was possible
to speed up the construction sequence
considerably: Six months‘ time saved in
comparison to transport via mixers.
Concreting
A stationary concrete pump BSA 2109 H
E (later a BSA 2107 SHP E) pumped concrete
via a delivery line that was permanently
installed in the tunnel from above
ground to the arch and base car riages,
which were a maximum of approx.
1,400 m away.
At times, the base concreting ran ahead
of the arch by up to 600 m. To feed the
arch formwork carriage, the delivery line
was branched off at an appropriate point
and a delivery hose was used to guide
the concrete into the stationary relay
pump BSA 1408 E directly at the formwork
carriage. Short distances between
the crew of the formwork carriage and
the pump machine operator prevented
compressive stress peaks in the formwork
carriage.
A P 715 fine concrete pump was available
for the concreting of the cross cuts.
Cleaning
The DN 150 delivery line was cleaned
by using water to force the concrete residue
out in a „forwards“ direction. Depending
on the length of the line, this
work was carried out by a BSA 2109 H
D or a BSA 1409 D. „Forwards“ water
cleaning is usually selected for relatively
long concrete delivery lines in order to
prevent large quantities of concrete residue
from forming. A replacement pipe
is then equipped with a media separation
system in order to separate the concrete
from the water when the concrete
residue is being forced out and, after
the concreting process is complete, it is
put in use directly behind the stationary
pump. The replacement pipe mentioned
above is usually fitted with a combinat-
ion of sponge balls and wash-out pigs.
Suitable media separation systems must
be configured depending on the concrete
delivery line installation. They are an
important part of the delivery line planning
to ensure the availability of the stationary
concrete delivery facility.
The BSA 2109 H E (from April 2009, this
is a modified BSA 2107 SHP E) pumped
approx. 28 m 3 of concrete per hour over
the distance mentioned above to the
arch or base formwork carriage.
Concrete
A tunnel section of 20 tunnel segments,
each 10 m long, was produced from
self-compacting concrete (SCC). For this
purpose, the Pöyry Infra GmbH (MVA
Strass) laboratory developed a concrete
mixture that was specifically formulated
for this delivery process.
The mixture breakdown of the SCC/
WDI/BBG concrete (see the concrete
u The formwork carriage at the front
is the base formwork carriage. The prepared
steel reinforcement can be seen at
the end of this carriage.
u The formwork elements are filled
using a type of rotary distributor. The
BSA 2109 H E directly supplies this with
concrete.
10
6 PM 4377 GB PM 4377 GB 7

The new 42-5 The new 42-5
Revolutionary!
The next generation of the 42-5
11 12
Fifty years of experience in the development
of concrete pumps means innovations
time and again. These innovations
revolutionise the pumping and delivering
of concrete. This is always based on
the tried and tested, robust concrete
pumps from Putzmeister, which are constantly
being improved upon and adapted
to meet modern demands.
With the 42-5 from the new generation,
we have gone one step further: We took
the basic idea and then completely rethought
and redesigned it. Countless
suggestions from customers, operators,
suppliers and Putzmeister employees
have flowed into the project.
From this emerged an innovation that is
setting standards on the market.
No fear of the scales
The resulting new design, from the boom
tip to the base structure, makes a gross
weight of less than 32 t pos sible, incl.
sufficient reserves for payload, equipment,
water and fuel.
Better in every respect
The concept for the new 42-5 was completely
revised and scrutinised, always
with the operator in mind. The 42-5 has
gained increasing importance when it
comes to operation, safety, operat ing
costs and service in particular.
Calculated and tested
All essential components have been calculated
using modern methods. Extensive
field tests verify the maturity and reliability
of the machine.
p Service-optimised and easy to retrofit thanks to the screw-fitted pipe bracket and
exclusive use of standard delivery line bends. For example, only three types of standard
delivery line bends are now used, whereas seven types were used in the past.
p The fluid cooler that is integrated into
the support leg ensures optimal cool ing
of the hydraulic fluid, even in OSS operation.
www.thenew42-5.com
13
8 PM 4377 GB PM 4377 GB 9

18
The new 42-5 The new 42-5
p The new Ergonic Graphic Display clearly displays all of the relevant data for the
machine. Shown here: Overview of the system status and fault management
14
15
Between June and the end of October
2011, two machines from the new 42-5
series are being used almost every day.
The tours are passing through South
Tyrol, Switzerland, Austria, Germany,
Finland, Sweden, Denmark and Luxembourg.
From September, a 42-5 will also be on
the road to construction sites in the hot
climate of Qatar. This is a particular hardness
test for the machine because, in
addition to the demanding climate conditions,
very difficult concrete mixes will
also put to the test the machine's suitability
for daily use.
Pay no attention to external conditions.
During a field test, all types of construction
sites are in operation: Bottom plates,
walls, decks, tunnels, etc. Only the width
testing finally shows the machine's
comprehensive reliability when used in
pract ice at a later point.
All field test machines are equipped with
a wide range of sensors which monitor
the hydraulic system and many other
functions. Regular inspections deliver
results mainly regarding the mechanical
condition of the machines.
This and, most importantly, the feedback
from the machine operators are
incorporated in the optimisation phase,
with the aim of being able to offer a product
at the start of series production that
has been completely field-tested. n
The field test with
two new 42-5:
On the road for
five months
q Uwe Fischer from
"a3 Beton" went for a
test drive with the new
42-5 in Switzerland
20
ÄÄWhat do the people who
work with the new 42-5
have to say?
"I particularly like the steady boom –
also, the machine as whole works very
smooth during pumping."
Uwe Fischer, a3 Beton, Switzerland
"The machine moves with agility on
our windy, mountainous roads. The
low weight and the short wheelbase
are perfect for this. Putzmeister has
done a very good job – you can sense
the high quality of the machine."
Hans-Karl Huber, Rienz Beton, Italy
"I like my old 42-5, but the boom on the
new 42-5 moves superbly. Above all, it
responds really well to the controls."
Ville Sinko, Transsinko Oy, Finland
"I really like the machine – and not
just the look of it. It is somehow elegant.
All of the parts are easily accessible
and Putzmeister even had us
machine operators in mind with their
accessories. I would love to be able to
keep this test machine for myself."
19
Volkmar Spies, Die Pumas, Germany
22
p Water tank with 800 l capacity (as standard)
16 17
21
p The sponge ball is always accessible in
the container.
p Delivery notes are stored securely in
the watertight, lockable docubox.
10 PM 4377 GB PM 4377 GB 11

50 Questions 50 Questions
Technology · Question 28
What does Putzmeister do
against wear and tear?
23
24 25 26
Chippings arise when planing. And
wherever concrete flows, scratches arise
from stones - extra hard coatings and
double-walled conveying pipes ensure
that the wear and tear is kept within reasonable
limits.
The material suffers wear where concrete
flows along machine elements – in the
concrete hopper with pipe branching, at
the mixer, in the pump and especially in
the conveying lines. This is what we call
sliding abrasion.
"How many cubic metres does your line
hold?", customers ask regularly. That depends
on what type of concrete is used
and how much is being conveyed. Wear
mainly depends on the type and distribution
of the aggregates (particle-size
distribution curve), the proportion of
the binding agent (cement and/or quick
ash), the water/cement ratio (water/cement
factor), as well as the shape, hardness
and porosity of the aggregates.
In Germany alone the degree of hardness
of the aggregates differs depending
on the region between factor 15 – 20.
With so-called "ball bearing concrete"
compris ing soft rounded gravel, one
can pump a good 60,000 cubic metres
of concrete using typical pipe lines at
a conveying quantity of 60 - 70 cubic
metres per hour. If one pumps concrete
with extremely hard, broken material
in the same line, then the concrete line
only stands approx. 4,000 cubic metres.
High-tech metallurgy controls
wear and tear
To minimise sliding abrasion, Putzmeister
concentrated on specially hardened
conveying pipes from early on. Today
there are conveying lines with two layers.
They comprise an outer pipe and an
inner pipe made from highly resistant
material.
Armoured elements last longer
The components of the concrete pump
are also armoured: A multi-layer special
coating made from chrome protects the
conveying cylinders which are particularly
prone to wear and tear. With this
coating Putzmeister guarantees a pumping
quantity of at least 100,000 cubic
metres – also for the most aggressive concrete
mixes. The pipe branching where
the cross-section of the concrete flow is
reduced and wear and tear is particularly
high, comprises a highly resistant
special cast steel or is armoured with
highly resistant steel facing.
Data and technology enable
the wear and tear to be calculated
Putzmeister developed a database to
calculate the wear and tear. It contains
information on the wear properties of
aggregates in many regions all over the
world. As the wear is also dependent on
the pumping speed, the concrete pump
measures the strokes per operating time
and thus calculates the average pumping
performance. Reliable statements on the
wear-resistance of components can therefore
be made – provided the customer
always pumps concrete with the same
wear properties.
Leader thanks to low wear costs
Putzmeister products suffer notably less
wear and tear thanks to the implementation
of many measures. The wear costs
per cubic metre of concrete amount to
40 – 60 cent for the entire machine.
Many customers undercut this value by
pump ing slower, resulting in reductions
in wear and tear and energy consumption.
In the meantime, the computeraided
concrete pump control supports
operat ors in the wear-reducing operation
of machines with the "Ergonic® Output
Control (EOC)" function for example.
Thanks to the wear measurement data
and the tele-service the wear and tear
can also be monitored remotely. The
data shows when it is time to replace a
part. The Ergonic® control systems from
Putzmeister thus permit preventative
maintenance. n
28
u Intensive wear or not?
Examples for concrete mixes from four
countries: The particle-size distribution
curves of aggregates are shown here.
The more adverse the particle-size distribution
curve and the lower the water/
cement factor, the greater the wear and
tear. This effect is further influenced by
the surface structure of the aggregates.
From left to right: Rounded pebbles
from Austria; Broken stones from India
and Dubai; The samples from Turkey
on the far right have really sharp edges
and are hard. The aggregates also differ
within a country from a region to region.
For example: Hard metal wear parts
p Hard metal wear plates with two to
four times longer service life compared
to DURO 22 (standard)
27
The parts of a concrete pump which
are in direct contact with the generally
strong abrasive medium are subject to a
variety of wear conditions:
• Sliding abrasion on both contact
surfaces of the wear parts
• Blast jet wear on the outer edges
of the wear ring and inner edges
of openings on the spectacle wear
plate
• Impact stress at the parting plane,
between the spectacle wear plate
and wear ring
• Flow abrasion on openings of the
spectacle wear plate and ring
Hard metal wear parts increase the
service life of the concrete pumps
Hard metal wear parts comprise a basic
body (structural steel) and an approx.
5 mm thick hard metal wear layer.
Hard metal wear parts have been
available from Putzmeister for approx.
20 years.
Different versions of hard metal wear
plates have been developed and used
from years of experiences with extreme
applications in concrete conveying
(e.g. Burj Khalifa).
12 PM 4377 GB PM 4377 GB 13

On site
On site
28
29
M 58-5
M 62-6 M 58-5
M 62-6
M 52-5
RV 10
M 63-5
M 58-5 M 58-5 M 63-5
Expansion at
Frankfurt Airport:
Large concreting work
of taxiway bridges for the
new North West runway
The precise planning of the locations was fundamental so that the work areas of the large boom truck-mounted concrete pumps
could be met. A M 58-5 and the M 62-6 were used on the north side and a second M 58-5 and a M 63-5 were on the south of the
taxiway bridge.
30
DIE PUMAS Betonförderung GmbH & Co.
KG is domiciled in the Rhine Main area
with 30 truck-mounted concrete pumps
with boom sizes of 24 to 63 m and stationary
concrete distributing systems.
Some of the longest distributing booms
of PUMAS were used in August and September
2010 in the large concreting work
on the taxiway bridges at the Rhine Main
Airport.
The two taxiway bridges lead over the
motorway and ICE line and connect the
new North West runway 07L/25R to the
current airfield. The new landing strip
should be in operation for the 2011/12
winter flight schedule. The first sod was
turned in May 2009.
West taxiway bridge –
concreting August 2010
The West bridge was able to be concreted
efficiently and on schedule thanks
to the exact planning of the locations
by four Putzmeister large boom pumps.
The superstructure was tackled with a
M 63-5, a M 62-6 and two M 58-5 on
20.08.2010 at approx. 20:00. Within 20
hours 3,240 m³ of concrete was placed,
which was made available in due time
by the suppliers Sehring Beton GmbH &
Co. KG.
14 PM 4377 GB PM 4377 GB 15

On site
On site
31 32
p The second machine on the south side, a M 58-5, had to be set up in the crane runway.
East taxiway bridge –
concreting September 2010
After weeks of planning, the superstructure
of the East taxiway bridge was concreted
on 17.09.2010. A M 62-6, a M 58-5
and a M 52-5 were used on the north
side, as well as a M 63-5 and M 58-5 on
the south.
The superstructure with a width (E-W)
of 345 m and a depth (N-S) of 91.5 m
was divided into three concreting phases.
Work began on the deepest part of
the structure where the ICE line and
both sides of the A3 motorway run.
In the planning stage an placing period
of 61.5 hours and a volume of 10,100
m³ were assumed. The guarantee of an
uninterrupted concrete supply from four
placing crews by the concrete pumps
from PUMAS was the main requirement
for the possible first smooth concreting
of almost 19,000 m².
As despite the use of large boom pumps
there was still a gap in the work areas of
the placing booms, a rotary distributor
p Neat parking: The M 52-5 found a suitable and secure installation site at the ICE line thanks to OSS
33
16 PM 4377 GB PM 4377 GB 17

On site
On site
34
ÄÄExpansion for more flights at
Europe's third largest airport
(Source: Ausbau Aktuell, March/2011)
In January 2011 the focus was on the
excavation work for the dams for the
taxiway bridges. To avoid pressure
from the dams on the abutment walls
of the taxiway bridges, which lead over
the motorway and ICE line, so-called
earth pressure traps were positioned.
The concreting work for the 45 m wide
and 2,800 m long runway is contin ued.
The "completed" ones began with the
concreting of two layers, each 11.25 m
wide, in order to complete the missing
part within 24 hours. The concreting
work for the flight operation areas
(runway and landing strips) will be
completed by the end of May 2011. As
soon as the work on the dams is complete,
concrete will also be applied to
the taxiway bridges. The aim is to also
complete the full five bridge structures
by May.
The commercial airport Frankfurt am
Main is by far Germany's largest airport
and, at the same time, is one of the
world's most important aviation hubs.
Measured in terms of passenger figures
it is the third largest airport in Europe after
London-Heathrow and Paris-Charles
de Gaulle and is number 9 in the world.
After the airport in Paris, it has the second
largest volume of cargo out of all
European airports.
The new runway should make possible
a coordination benchmark figure of 126
flights per hour at the airport in Frankfurt.
q Graphic of the new runway 07L/25R with the two taxiway bridges
36
ÄÄwww.ausbau.fraport.de
35
p The M 63-5 also mastered this critical
part of the concreting over the lane of
the A3 motorway reliably and in a total
of 34 hours!
37
p "Approach" of the rotary distributor
RV 10, which further extended the working
area of the M 58-5 in the centre of
the taxiway bridge at the east.
RV 10 was also used. This was used only
at the start for 150 m³. All other areas
could be reached directly by the booms
of the truck-mounted concrete pumps.
The RV 10 was fed by the M 58-5 on the
north side of the taxiway bridge.
The M 63-5 was assembled directly on
the motorway of the A3 motorway heading
toward Frankfurt and had to convey
the concrete over the lanes onto the
bridge. This called for the highest safety
requirements. For this reason the complete
piping of the machine was replaced
before the commencement of the work.
A fifth concrete pump, a M 52-5, was
assembled north of the bridge between
the ICE line and the A3 motorway in the
direction of Cologne. It connected directly
at the work area of the M 58-5 in an
eastwards direction.
After almost 20 hours and 3,700 m³ of
concrete the first section of the superstructure
was concreted.
The concrete pumps were able to be used
again without a location change for the
start of the second section. The mid-section
of the bridge concreted in the first
section was finished with power trowels
in the intermediate stage. Eventually
after 46 hours and approx. 8,200 m³
the booms of the concrete pumps reached
their final locations. n
18 PM 4377 GB PM 4377 GB 19

On site
On site
40
38
39
Uttarakhand / North India:
1100 m – new Indian
record in long-distance
concrete pumping!
p Placing of the concrete in the casings at the tunnel walls to support the roof
q The Putzmeister project team after
the successful concreting
41
A stationary concrete pump, type BSA
1409 D from Putzmeister, created a new
record in December 2010: 1100 m in a
tunnel is to date the widest distance
achieved in India.
The tunnel – 3 km long and with a diameter
of 2.50 m – is part of the Bhilangana
III hydro power plant with capacity
of 24 MW. The power plant is located in
Ghuttu, Tehri Garhwal, in the north Indian
state of Uttarakhand.
With regard to the land, the project was
a huge challenge for all concerned. The
entire concreting logistics were developed
in Ghuttu – the last point that can be
reached by road at the Bhilangana River.
Detailed planning, from a suitable installation
site for the pump to the laying of
the pump line and mounting the casing,
was essential for ultimate success.
The concrete pump was set up against
the pump direction for more stability.
From the hopper outlet the pump line
continued initially over two 90° elbow,
which reduced the transfer of the pressure
in the line to the pump. The pump
line was screwed to the concrete bases
using U-shaped supports. A shut-off
valve in the delivery line prevented the
20 PM 4377 GB PM 4377 GB 21

On site
On site
backward flow of concrete and water as
the tunnel pipe continued on diagonally
and had a downward slope against the
concrete pump. A specially produced
concrete block over the pump line before
the tunnel entry detected the force
of the pump.
The tunnel concreting required a continuous
pumping process of 105 m 3 of
concrete of strength class C25 into the
1,100 m distance. For the team, this
meant concreting day and night, in sections
of 67 m long for the roof and side
walls and 70 m for the base. If the end of
a casing section was reached, the base
was then concreted in reverse direction.
The concrete was placed using an elbow
pipe. The thickness of the concrete layer
was between 200 and 250 mm. The
concrete mix was monitored constantly
before and during concreting. n
42
p A shut-off valve prevented the backward
flow of concrete and water from
the pump line which had a downward
slope.
u In the Pooja ceremony concrete
pumps and equipment received divine
blessings for the demanding task ahead.
45 46
p The concreting team were working in
the tunnel around the clock
43
Technical data BSA 1409 D
Output up to 94 m 3 /h
Concrete pressure up to 106 bar
Drive
140 kW (Diesel)
Delivery cylinder Ø 200 mm
Stroke
1400 mm
State
Uttarakhand
INDIA
NEPAL
CHINA
Ä Ä"When two rivers meet,
only one continues on"
The Bhilangana River is the main tributary
of the Bhagirathi, the source river
of the Ganges. It rises at the foot of the
Khatling glacier in the Central Himalayan
region of the Indian state Uttarakhand,
which is bordered in the North
by Tibet and in the East by Nepal.
47
ÄÄDiverse path to
the top of the world
The popular trekking route from the
mark et town Ghuttu to the Khatling
glacier runs alongside the river (3,717
m MSL). It flows initially through thick
forests and wonderful lush green meadows.
Further on it encounters passes
over 5000 m, glacier moraines and snowfields.
Trekkers rave about this multi-day tour.
Impressive views of the giant Garhwal
Himalaya make up for the effort along
the difficult route.
49
Ghuttu
48
44
Bhilangana
Putzmeister India ensures
competent assistance at any time!
Bhagirathi
Putzmeister offers its Indian customers
round the clock service, 7 days a week,
via a central, free telephone number.
Ganges
The West wall Nanda Devi – at 7,816 m is the second highest mountain in India.
22 PM 4377 GB PM 4377 GB 23

On site
On site
50 51 52
Putzmeister's rheometer in use on the
construction site
A new measuring device is available to
examine the concrete. "The "Sliding Pipe
Rheometer" – SLIPER for short – developed
by Putzmeister enables a quick advance
assessment of the pumpability of
concrete or other thick matter in the lab
and on the construction site.
"Using the rheometer the time and effort
spent on pumping tests can be reduced
and thus costs saved. At the same time,
this new technology facilitates a quality
check, as well as a simple prognosis option
with regard to the pumping behaviour
of concrete and other thick matter,"
states concrete technologist Dr. Knut
Kas ten from Putzmeister.
Delivery pressure
Concrete mix A
Concrete mix B
Output
p The diagram shows the fundamental
independence between concrete pressure
and output.
u Measurement on the construction site
using the Sliding Pipe Rheometer
53
Stable platform for
wind power –
Heavy bases for offshore
wind power systems
As part of the "Wetfeet" project, preparation
for the implementation of heavy
bases for offshore wind power systems
is currently underway. Here the wind
power systems are to be manufactured
completely on land with a concrete column
and a concrete base and then transported
to sea by a purpose-built ship.
STRABAG Offshore Wind develops, designs
and realises heavy bases for wind
energy systems that are ready for use for
offshore wind farms. Using a concept of
complete standard system assembly on
land, STRABAG offers decisive advantages
here. With the completion of the
new STRABAG terminal in Cuxhaven
Offshore Wind is now able to undertake
large-scale production.
STRABAG is investing over 300 million
Euro in total in these manufacturing
sites in Cuxhaven. Up to 500 jobs are
planned to be created over the coming
years as part of the initial development
phase.
Wind power system is assembled fully
on land
"A special feature of the STRABAG logistics
concept is the pre-assembly of
the entire wind energy system, comprising
steel tower, turbine and hub with
rotor blades, on the heavy base in the
product ion plant in Cuxhaven", states
Dr. Klaus Weber, Managing Director of
STRABAG Offshore Wind GmbH. The
7000 ton system is then transported by
a purpose-built ship to the wind farms.
Thus offshore installation is largely independent
of weather and sea conditions.
For installing a parts plant of this size –
the factory grounds stretch over 50 hectares
– many details need to be examined
and tested in advance. As a preparation
for the later series production and for the
examination of loading at the base, a test
base for such a wind power system is
being manufactured in Cuxhaven.
Concrete pumps are to be used for the
efficient manufacture of bases. The high
requirements of the properties of the
concrete have effects on the pump behaviour.
To test this, in the case of concreting
measurements of the concrete
pump are taken and, at the same time,
examinations of the concrete mix using
a recently developed rheometer are performed
by Putzmeister.
On an automatic concrete pump, type
BSF 42-5.16HLS, the concrete pressure
in the line behind the hopper has been
measured. With this the pump behaviour
of the special concrete C70/85 is
analysed for conditions prevailing on the
construction site.
Consistent measurements at the pump
and using the rheometer have shown
what properties the concrete has when
pumping: As can be frequently observed
with modern high-strength concrete
mixes, this special concrete also generated
relatively high pressure drag in the
conveyor pipe. The properties determined
through experiments help in the
targeted and clever design of later pump
systems.
The examinations using the rheometer
are offered exclusively as a service. n
ÄÄTail wind
The continuous development of renewable
energies in Europe is leading to
more and more wind energy systems
being installed not only on land, but
also in areas in the North Sea and the
Baltic Sea.
p Here offshore wind power systems will be manufactured completely on land in the
future.
54
In the late summer of 2009, the German
government concluded a development
plan, according to which by 2030 up to
25,000 megawatts could be generated
using offshore wind power. According
to the Ministry of Transport 30 wind
farms are to be built in the North Sea
and 10 in the Baltic Sea. Germany lies
in second place behind the USA as the
biggest wind energy producer.
24 PM 4377 GB PM 4377 GB 25

Putzmeister Solid Pumps
Putzmeister Solid Pumps
Putzmeister Solid Pumps
for ship and offshore
applications
t Rem Hrist next to the drilling
platform „Deep Sea Atlantic“
55
Technical data:
Scope of supply for each vessel
2 x sliding frame PDL 6845
2 x auger feed device SHS 4552 SH
1 x high density solids pump
KOS 1480 HPS
1 x power pack HA 200 E-SP
1 x control cabinet SEP 200
1 X boundary layer injection unit
250/600
57
Technical key data – PSP pump system:
Storage tank for
drill cuttings 2 x 200m³
High density
solids pump
50 m³/h, 60 bar
Technical key data – supply vessels:
Total length
88,8 m
Width
19,0 m
Depth of main deck
Max. draught
Design draught
Net Tonnage
Gross Tonnage
Max. speed
8,0 m
6,6 m
6,0 m
1328 NRT
3969 GRT
15,4 Knots
PSP’s scope of supply:
• Sliding frame with driving cylinder,
located in the storage tank (grey)
• The discharge and auger feed device
is underneath the hydraulic gate
valve (blue)
• High density solids pump (yellow)
• Hydraulic power pack with boundary
layer injection (not illustrated)
p The installed solids pump can be seen
by the hopper’s white cover lid in front
of the person. The auger feed device can
be seen in the foreground.
56
Statoil, the Norwegian oil and gas company,
is Europe’s most important supplier
of natural gas and belongs to the
world’s largest crude oil sellers. The company
operates numerous drilling rigs and
production platforms in the North Sea,
North Atlantic and the Barents Sea (offshore).
The enormous price increase for
crude oil leads Statoil to ever increasing
drilling depths, which is currently at 4000
m.
According to Norwegian law, until 1991,
drill cuttings were permitted to be dumped
on the sea-bed, next to the bore hole.
Currently, the threshold values for the
residual oil content of drill cuttings, still
stored at sea, are at one gram per kilogram
oil. Exempted are cold water areas.
For example, in the Barents Sea, there is
a zero-emission limit value.
Due to these regulations and the limited
available space, the further treatment of
drill cuttings is carried out on land.
Up until now, the drill cuttings were
transported from the drill rigs via closed
transport containers or via vacuum tanks
(filled by vacuum pumps) that were then
emptied on land.
Loading these containers and tanks by
crane on the supply vessels is a timeconsuming
task and risky in case of bad
weather.
In order to improve the loading and unloading
tasks on the supply vessels, the
conveyance of drill cuttings with the help
of piston pumps and pipelines is very
useful.
Ulstein Werft, one of the most innovative
shipyards in designing special vessels for
the oil and gas industry, has won the tender
launched by Statoil in 2008 to build
two supply vessels. Putzmeister was
chos en to deliver the storage and pumping
system for the drill cuttings.
The reason for choosing Putzmeister’s
system was the long-standing experience
in the conveyance of different kinds of
difficult flowing materials and also the
successful drill cuttings pump tests done
in 2007 and 2008.
Despite the scarce available space, the
whole unit was able to be installed in the
cargo department in a service-friendly
manner.
Long years of experience in project business,
great teamwork and co-operation
with the Ulstein Werft’s ship building engineers,
as well as a high level of expertise
in project management were the factors
that enabled us to comply with the
delivery date, the project’s budget and
the high standards set for ship building.
Both ships with yard numbers 288 and
289 were delivered on schedule to the
company Remoy shipping, which has an
8-year charter agreement with Statoil.
The vessels were named Rem Hrist (288)
and Rem Mist (289).
Besides the storage and pump systems
for drill cuttings, the supply vessels have
a Multi Cargo Tank System for liquids
and dry solids. Furthermore, on deck,
they have approximately 1,000 m² of protected
area for containers.
59
In case of an oil leak, like the one that
happened with the Deep Sea Horizon,
drill cutting tanks and the Putzmeister
pump system can store and pump ORO
(water mixed with oil).
In connection with these assignments,
PSP service technicians underwent a special
offshore security training of several
days in Norway. n
t Deepsea Atlantic’s drill cuttings
coming from the shaker. These drill
cuttings are then stored onto the supply
vessels.
u Rem Hrist in Ulstein Werft’s dry dock
during the installation operations of the
PSP pump system.
ÄÄThe Valkyries Hrist and Mist
come from the Norse mythol ogy.
Valkyries are female ghosts from
Odins entourage and select fallen
warriors that will reach Odin’s castle
Asgard in the afterlife. Once there,
they become so-called Einherjer.
60
58
26 PM 4377 GB PM 4377 GB 27

In brief
In brief
Caution:
Snappy ad!
"Since I have the eye-catching writing
on my M 52, my customers are ordering
nothing but the "Big Dog", states
Robert Heider, Managing Director of
the concrete pump services Heider
from Wolfegg im Allgäu. As he was
in the area, he made a pit stop at the
Putzmeister plant in Aichtal.
42
uRobert Heider (right) and
Jörg Hermann, Manager of
the Workshop Service Centre
in Aichtal (left)
61
In the Putzmeister Post 79 we reported
on the spectacular concreting at the
double arch of the Hoover Dam bypass
bridge which was effected in October
2009.
A year and a half later in April 2010 the
bridge was once again the scene of an
exciting event: A M 52 was "flown" to
its airy workplace by cable crane.
A total of eleven fields, each 27 x 37 m,
of the future road had to be concreted.
Pump service providers Quinn from
Las Vegas, who were assigned the entire
project with regard to equipment
and machine operators, were in demand
with their M 52 as a semi-trailer.
The large range was decisive in the
choice, but also its semi-trailer configuration.
The truck-mounted concrete
pump was able to be "alleviated" with
its tractive unit and positioned on-site
on a special counterweight using a
crane.
The M 52 was positioned at the peak
of the arch. To distribute the load
symmetrically and balance the bridge
arch, it concreted one area on one side
and then one area on the other side.
Always rotating until all eleven areas
were complete.
The rotation of the pumps was necessary
as the supply line from the stationary
concrete pumps, which fed the
M 52, would otherwise have been in
the way.
The Hoover Dam bypass bridge has
been in operation since October 2010
and is called the "Mike O’Callaghan
– Pat Tillman Memorial Bridge". The
construction of the almost 610 m long
bridge took roughly five and a half
years.
62
M 52 approaching
the Hoover Dam
bypass bridge
63
28 PM 4377 GB PM 4377 GB 29

In brief
In brief
In the Saudi Arabian capital Riad
construction has begun on the "King
Abdullah Financial District" (KAFD).
The ambitious project with a volume
of 10 billion US$ will comprise more
than 40 skyscrapers on an area of 1.6
million m 2 and should be completed
within a construction period of just
three and a half years.
"Saudi Arabia is to become the financial
centre of the Middle East." This proposal
and the large personal interest
of the head of state and government
King Abdullah bin Abdulaziz Al Saud
are helping the project to advance
quickly and consistently. Construction
of the first 10 of 40 lots began at the
end of 2009; after only 30 months they
should already be complete. The same
short construction period is estimated
for the other sub-projects. 70 % of the
building should be complete by the
middle of 2012.
The concept of the KAFD not only envisages
exclusive offices for financial
companies. Approximately one quarter
of the 5 million m 2 building area is
intended for residential apartments.
Six hotels are planned, as well as
numerous shops and leisure facilities.
What is important for the builders is to
create a pulsating city in the day and
at night and to create a harmonious
connection between work, living and
leisure.
According to the principle of a "Wadi" – a
Wadi describes a dry riverbed which contains
water only during times of heavy
rainfall – in the entire complex there
are shaded footpaths with water features
and plants, as well as lots of airconditioned
"sky walks" between the
towers and a single-track rail around the
district. Each skyscraper has four under-
Large project in Saudi Arabia:
King Abdullah Financial District
ground car parks. Together with the
complex traffic routing, the KAFD remains
practically car-free.
The quantity of concrete required for
the construction of 1.6 million m 3 is gigantic
– 2000 m 3 should be used every
day.
Putzmeister is helping with this project
not only with reliable pumps and
placing booms, but is also on hand to
provide project advice.
64
65
Telebelt reduces the
costs of placing mass
concrete in Chinese
shipyard
Titan Quanzhou Shipyard Co. in Hui’an,
Quanzhou in the Chinese province of
Fujian is part of the Titan Petrochemicals
Group Ltd. The shipyard consists of
a cofferdam, an outer quay and four
dry docks. Dock 1 is the main shipyard
and consists of the dock entrance, wall,
foundation, passage, drainage system
and pump house.
The project started in 2006 and the
concreting work began in March 2010.
The first and second docks are due to
be completed by the end of May 2011.
For the concrete placement, the main
items of equipment being used are a
Putzmeister Telebelt TB 110 G, three
12 m 3 truck mixers and one 3 m 3 mixing
facility located 500 m from the
construction site.
Large quantities of concrete used for
the foundation of the shipyard
entrance and the pump house
The foundation of the pump house, for
example, is 54 x 41 m and 2 m thick
with a total of 4,800 m 3 of concrete.
To construct this foundation, concrete
had to be conveyed continuously. No
problem: Telebelt operated without interruption
for 67 hours and completed
the job perfectly. The fuel consumption
was measured during the placement.
The result: 1,000 litres of diesel for 5,300
cubic metres of placed concrete.
Telebelt concretes the dock wall
The concrete for the dock wall was
poured in three layers and the maximum
height of the wall was 12.6 m. The Telebelt
was set up directly at the wall.
And, with the conveyor belt's maximum
working height of 18 m, the Telebelt
had plenty in reserve for the operation.
When concreting the walls, the quiet,
no-vibration conveyor belt was more advantageous
and reliable.
The perfect conveyor belt for the base
plate of the dock
The foundation plate was 60 cm thick
and the entire surface was divided into
several segments, with each segment requiring
225 m 3 of concrete. The big advantage
of the Telebelt in this case was
its ability to convey the concrete horizontally.
Ideal and time-saving for this
type of concreting.
66
ÄÄTitan Quanzhou Shipyard
The location of the Titan Quanzhou
shipyard on important merchant
shipping routes and its relatively
close proximity to important ports,
such as Shanghai (502 nautical
miles) or Hong Kong (386 nautical
miles), make it an ideal point of approach
along this coast.
The shipyard is expected to be operational
in 2012, when it will become
one of the largest in the world, with
huge capacities for repairing and reconstructing
supertankers (VLCC),
large bulk carriers, RORO ships and
even the largest container ships that
are currently sailing the world.
The shipyard comprises 110 hectares
of land with a coastline that is 3.6
km long.
The dimensions of the docks
Dock 1
Dock 2
Dock 3
and 4
380 x 80 x 14.4 m
420 x 68 14.65 m
each is 280 x 46 x 12.8 m
Save money and time with the reliable
Telebelt
Telebelt can convey concrete with a
low slump and a relatively large particle
distribution. Concrete mixes of
this kind are mainly used as mass concrete
because, on the one hand, they
produce less hydration heat and, on
the other, they are significantly less
expensive than pumpable concrete. As
a result, they considerably reduce the
costs for a project such as this one.
In comparison to other methods of
concrete placement, the TB 110 G has
saved a lot of time thanks to its large
output and high level of mobility.
Since the beginning of the concreting
work, the Telebelt was extremely reliable
to use. Except for scheduled
service work, there were no downtimes
during this time.
By September 2010, the TB 110 G had
already placed 45,000 m 3 of concrete
and, by April 2011, it had pumped as
much as 130,000 m 3 on this shipyard
construction site.
[Putzmeister Machinery Shanghai Co. Ltd.]
30 PM 4377 GB PM 4377 GB 31

Putzmeister Services information:
Longer service life
for your delivery line
Sponge ball
for Ø 120, 125, 140
• Every ball now packed
with dirt-resistance
• Now even more tear-resistant
• Optimal resetting properties
5.10 €
part-no. 018841002
67
Clean
& Tight
68
The prices quoted are net prices EXW Aichtal, as at 05/2011.
Prices become invalid upon the publication of new price lists for spare parts.
Set of seals * SK 125 5,5Z
• Increases the service life
of the seal in the swivel
• Use in typical SK 5.5"
couplings possible
4.10 €
part-no. 484216
More informationen is available from:
Tel. +49 (0) 7127 599 297 · spareparts@putzmeister.de
* Seal and storage (blue)
PM 4377 GB