2005 - Putzmeister

The Magazine for our Customers and Friends 64
PM 3723 GB

Contents
Latest News
2
PM 3723 GB
3
4
Latest News
Record number of participants
Information from VDMA
Colossal hangars for superjumbos
Title Story
Refurbishment
12
15
25
Not as easy as you think –
Diamant Mühle Hamburg refurbishment
Building construction
Large construction site
16
Power station construction
in Canada's wilderness
Background
10
20
24
Technology
14
"Quintuplet" adapts itself
Between sun and sea
Numerous concrete pumps
at Germany's largest construction site
Special concrete
22
26
New machinery means ideally
equipped to compete
High quality requirements even in the
construction of model concrete pumps
Ten in a row
Flexible 20 m "quad" –
Universal truck-mounted concrete pump
with an unfolding height of just 3.9 m
Concrete placement on 109 m high pit
frame
Large boom concrete pumps inject
"Bügelbauten" bookend buildings
Application
28
Concreting on water
22
5
20
4
3 4
new!
16
2
14
6
24
26
10
12
7
8
9
10
Record number of
participants
In December, the Putzmeister Academy is
looking forward to a record number of
seminar participants for the 2005 training
season. Within a year, over 1,100
Putzmeister guests from all continents will
have achieved further qualification in 61
customer seminars. The one- to five-day
courses are held either at Putzmeister's premises
in Aichtal or directly at the customer's
premises. The contents are aimed at
the operators of concrete pumps and at the
machine maintenance staff (mechanics,
workshop managers).
In order to reach as many participants as
possible in their respective mother tongues,
the PM Academy trainers offer the individual
courses not only in German and
English, but also in French and Spanish.
Translation into other languages, such as
Arabic, Russian, Chinese, etc. is carried out
on-site by qualified interpreters, depending
on the composition of the group of
participants.
For seminar season 2006, the Putzmeister
Academy has again extended its range of
courses. For more information, and to register
for a seminar online, see:
www.pm-akademie.de
Information from the German
Association of Machine and
Plant Engineering (VDMA)
The Chinese STATE DEVELOPMENT &
INVESTMENT CORP is planning to
invest approximately USD 17.3 billion in
the construction of six hydroelectric power
stations at the upper reaches of the
Yangtzee (Sichuan Province). One of the
projects has already been approved by the
responsible authorities and is to join the
mains supply by 2012.
It is estimated that the construction of the
Messina bridge, one of the largest Italian
infrastructure projects, will start in spring
2006. The contract to construct the 3.3 km
long suspension bridge over the Strait of
Messina was awarded to a consortium
under the management of the Italian construction
company IMPREGILO. The consortium
also includes the Japanese company
ISHIKAWAJIMA HARIMA HEAVY
INDUSTRIES, the Spanish company
SACYR VALEHERMOSO and other
Italian construction firms. The two towers
of the bridge will be higher than the Eiffel
Tower, at 383 m each. The costs of the
bridge designed for road and rail traffic, is
estimated at EUR 3.88 billion.
Colossal hangars
for superjumbos
Dubai International Airport, the major
international gateway in the United Arab
Emirates, has been expanding since 2002
thanks to investment totalling $ 4.1 US billion.
The project mainly involves the construction
of a third passenger terminal, two
concourses and one enormous air cargo
centre. Completion of the project will triple
the airport’s annual capacity from 22 million
to 60 million passengers. This increase in
capacity will be made possible by the
introduction of modern superjumbo aeroplanes.
In addition to the expansion of the takeoff
and landing strips of Dubai International
Airport, there is another major project
underway. A gigantic hangar complex is
under construction in which it will also be
possible to carry out demanding maintenance
work on any of the models in the
rapidly expanding fleet of EMIRATES
AIRLINE and its contractual partners. The
hangars are dimensioned to even be able to
house AIRBUS A380 superjumbos with a
wingspan of almost 80 m. EMIRATES
AIRLINE has already ordered 45 of these
superjumbos, which have ample room for
up to 850 passengers.
The new “Emirates Engineering Center”
includes eight hangars, workshops, a washing
zone, an aeroplane painting facility,
office space, two taxiways, a mosque and a
powerplant. The Putzmeister BSF 42.16 H
shown below will also be used for the
extensive concreting work.
11
3
PM 3723 GB

Title Story
Power station construction
in Canada's wilderness –
1200 km from the
nearest service
support point
The on-going energy development of
Hydro-Québec is part of a $2 billion project
undertaken by SEBJ – Societe
Energie de Baie James. For Hydro-
Québec, SEBJ has been instrumental in
the development of a very rich hydroelectric
area via numerous power stations
installed since the 1970s. The new
Eastmain-1 hydroelectric power plant –
located on the Eastmain River near James
Bay – is designed to generate 480 megawatt
of electric power for Hydro-Québec.
This was preceded by extensive negotiations
with the Cree Indian clans resident in
the region. Several different Putzmeister
machines are being used here in the
Canadian wilderness – far from any
service support point.
The enormous project – underway in a
desolate region in northern Québec – includes
a powerhouse, a main dam across the
Eastmain River, the spillway on the right
bank of the river, and 33 dikes for reservoir
closure. The construction of the project's
complex was broken down into five major
contracts, awarded independently via open
public bids.
12
The largest of all structures being built is
the 50 m tall, 125 m long and 55 m wide
powerhouse – where three huge turbines
will generate the power. This surface
powerhouse, built into a rocky hill, is on
the left bank of the Eastmain River. By the
time the water exits through the tailrace, it
will have dropped over 60 m from the
water intake. This head, combined with the
flow, develops kinetic energy that causes
the turbines and generators to turn, producing
electricity.
In particular, the major $ 108 million
Canadian powerhouse, penstocks, and
water intake project were started in the
spring of 2004 under the direction of
Canadian contractor AECON HOCHTIEF.
The AECON Group is one of Canada's
largest publicly traded construction companies,
and the group is 49 %-owned by
German construction giant HOCHTIEF.
Upon completion in early 2006, the reputable
general contractor will have pumped
over 46,000 m 3 of concrete. This amounts
to about two-thirds of the total 68,000 m 3
needed for the entire project.
Aggregates of granite, a little water and
low cement content
In order to guarantee the most economic
concrete placement possible, in addition to
efficient concrete manufacture, the site
management is absolutely dependent on
reliable machine equipment. For, in this
remote area, the failure of machines would
lead to extremely high costs – Montreal,
the nearest big city, is over 1,200 km away.
For this reason, AECON HOCHTIEF
decided on the Canadian representation of
Putzmeister, POMPACTION Inc., from
Pointe-Claire. It delivers practically all the
concreting equipment to the remote construction
site in the extremely sparsely
populated north-east of the country.
Project Manager Ken Chryssolor of
AECON HOCHTIEF said, "For over 30
years, I've worked on huge jobs within
James Bay so I know how difficult the
abrasive granite mix is to pump. As we
needed high performance equipment that
could handle the tough aggregate mix, we're
depending on all Putzmeister products."
Shorter boom for thicker lines
For the specific powerhouse and water
intake project, the mix of equipment
includes two BSA 2109 H-D high pressure
trailer-mounted concrete pumps, a JT 5000
jumbo trough mixer, and two PM towers
for mounting specially modified MXR
30 Z-150 separate placing booms. The two
Putzmeister placing booms were originally
standard MXR 34 Z-125 units modified by
shortening the boom length to 30 meters to
make up for the weight difference in using
the 150 mm pipe required.
Instead of typical 125 mm pipe, 150 mm
diameter was needed throughout the delivery
system in handling the extremely harsh
concrete mix supplied by the on-site batch
plant. The brutal mix comprises crushed
granite at 38 mm wide yet an inconceivable
100 mm long. Due to the abrasive mix, high
pressures, and up to 150 mm pumping distances
involved, Putzmeister ZX pipes and
couplings are also being used. In addition,
with generally lower water/cement values,
the concretes for many constructional elements
have hardly any free water and the
cement content is often significantly reduced
in order to reduce the hydration heat.
Particularly hard-wearing
ZX delivery lines
"We needed heavy duty pipe and couplings
for handling the extremely hard aggregate
mix and for long usage life.
Title Story
Putzmeister introduces three variants of
the ZX coupling system to the program:
The ZX-S
threaded coupling is especially suited
to quick assembly of delivery lines which are
seldom or never rerouted.
PM recommends
the ZX-K wing-head coupling for quick
assembly of delivery lines that have to be installed
more frequently.
The ZX-W wedged coupling was
developed so that delivery lines can be opened at
lightning speed, for example at emptying stations or
cleaning connections.
Putzmeister's special ZX pipe and couplings
are completely leak-proof and high-pressure
resistant. They definitely outlast any standard
pipe and are an absolute necessity for
this application," Ken noted.
Two Putzmeister BSA 2109 H-D trailermounted
concrete pumps were also selected
because of their field proven S-valve for
handling the coarse mix. They would also
help keep wear costs to a minimum with
their inherently long 2100 mm stroke
cylinders and up to 152 bar high-pressure
capabilities.
14
15
16
13
Without a set pattern, pumping occurs on
an irregular basis. Average outputs range
between 20 to 60 m 3 /h with the rate of
placement governed by the specifications
and the complexity of the intricate forms,
not by the equipment capabilities.
View of the dam of the Eastmain-1 hydroelectric power plant in north-east Canada.
The outlet tunnels are shown in the left of the picture (Photo: SEBJ)
4
PM 3723 GB
The concrete contains aggregates with an
edge length of up to 100 mm
5
PM 3723 GB

Title Story
Title Story
Concrete mixing trough as an
additional "buffer"
Of the two trailer pumps, one serves as the
main production unit being fed via a
Putzmeister JT-5000 jumbo trough – a surge
hopper directly flanged to the pump's hopper.
The jumbo trough with a concrete
capacity of 5 m 3 allows a quick and full
discharge of the mixer trucks into its large
capacity hopper. The buffer function of the
mixing trough means it is also possible to
continuously supply the main pump (max.
output 95 m 3 /h) with concrete.
The second Putzmeister trailer pump serves
as backup because cold joints are absolutely
forbidden or the powerhouse would be
structurally deficient. Consequently, in case
of an equipment malfunction, the second
pump can finish a pour.
Ken said, "We basically have to almost
duplicate equipment needs because of our
remote location 15 hours away from
Montreal. With 600 men on a job, we can't
afford down time. Fortunately, no major
problems have resulted to-date, and the
equipment has performed to our demanding
expectations."
17
From April to November 2004, concrete
work for the powerhouse took place. Two
24 m tall placing boom towers were
anchored with bolts and had to be precisely
mounted in specified locations so no cold
joints would interfere with the flow of
water upon project completion.
"Z" folds show their strengths under
the roof
The two placing booms – each using their
full 30 m horizontal reach – first provided
full coverage to place concrete for both the
walls of the huge turbines and the powerhouse
structure itself.
In November, the two towers were moved
to handle the intake structure. This time,
they were supported by 4.5 m x 4.5 m x
1.2 m high poured concrete mats, and the
placing booms still provided ample reach
to all concrete placing areas.
Especially noteworthy is the placing
boom's Multi-Z boom configuration, which
proved exceptionally maneuverable in
working under the low roof of a temporary
overhead steel structure. The structure was
specially built so construction could continue
during the frigid winter months.
AECON HOCHTIEF is also handling the
horizontal concrete work for the penstocks.
The three enormous penstocks are concretelined
conduits excavated in the rock to
channel water from the reservoir to the
powerhouse turbines and are designed to
maximize the head (drop in level).
A Putzmeister BSA 2109 H-D trailer pump
is pumping the concrete lining of these
107 m long penstocks, each at a 7.6 m diameter
ranging from a 0.3 m to 1.2 m
thickness.
Important: reliable machines
a n d good service
Besides the equipment's proven performance,
service and support capabilities were a
significant factor in AECON HOCHTIEF
selecting POMPACTION for their equipment
needs. POMPACTION assisted in
specifying the appropriate equipment, helped
train operators, and is making service
calls when deemed necessary.
19
Project manager Ken Chryssolor
(Photo: AECON HOCHTIEF)
18
The two PM MX 30 stationary booms are installed in 24 m high lattice towers (Photo: POMPACTION)
20
A Stationary concrete pump BSA 2109 H-D
B „Jumbo“ Trough mixer JT 5000
C ZX delivery line
B
A
C
6
PM 3723 GB
A MX 30 used for concrete placement in the turbine house. One of the inlet tunnels is shown in the background (Photo: SEBJ)
7
PM 3723 GB

Title Story
Title Story
And making service calls isn't easy. As a
closed site, entry is by invitation only via
SEBJ (Air Creebec) aircraft or a 15-hour
drive from Montreal. That's why a specially
developed workcamp was built to house
construction site workers, who in staggering
shifts work 42 days followed by a tenday
leave.
During a peak period in summer 2004,
nearly 2,400 workers were housed in dormitories.
Work is carried out in alternating
shifts, each lasting 42 days. There are then
ten days free. Similar to a mini-town, the
site offers a variety of services such as cafeteria,
hair salon, convenience store, post
office and library along with indoor and
outdoor recreational facilities.
Once the project is complete, the approximate
1.3 km 3 workcamp will be dismantled
and transported to another job site.
The TELEBELT was used to deliver hardcore,
sand, broken rock and also concrete to the
large construction site
21
Even the DYNAJET high-pressure cleaners
were on-site working six months for
NEILSON CONSTRUCTION of Québec
City. Next to the dam, two 500th models
sprayed water at high 500 bar pressures to
thoroughly clean selective areas of rock
before concrete placement was possible.
In summary, Francis Gagnier, Vice
President at POMPACTION said, "We've
sold several different pieces of Putzmeister
equipment to various contractors working
on this enormous and demanding project
complex. That alone is valid testimony to
the value placed on the equipment's performance
and reliability within such a remote
location."
As of spring 2005, the entire Eastmain-1
project was 66 % complete. Plans are for
the facility to be operational by late 2006.
23
24
Wide range
Besides building the concrete intensive
powerhouse, other construction projects on
site are also utilizing various Putzmeister
models, resulting in basically a monopoly
of Putzmeister equipment on Eastmain-1.
This includes a BSA 1409 electric-powered
trailer pump being used by NORASCON-
HEBERT joint venture, two companies
well established in Québec. The unit is
competently placing concrete for all incline
work associated with the penstocks.
In addition, a TELEBELT TB 105 belt conveyor
was utilized for placing concrete on
the main dam across the Eastmain River.
The contractor, HAMEL CONSTRUCT-
ION took full advantage of the conveyor's
special functionality to place unusually
tough mixes and other aggregates such as
sand, gravel and rock with ease.
For construction of the numerous dams,
various Thom-Katt trailer-mounted pump
models were utilized for shotcreting by
NORASCON-HEBERT and also by EDM
CONSTRUCTION, who were sub-contracted
by CCDC in Montreal. In addition,
a Putzmeister P-11 diesel-powered
rotor/stator pump handled injection grouting
for EBC, Inc.
We would like to thank POMPACTION,
PM America and Sheila Eden for their
assistance with this article.
Self-confident First Nations peoples
The Cree people are now one of the largest
First Nations groups in North America.
Their settlement area stretches from the
Rocky Mountains to the Atlantic coast, in
the north of the USA and in the south of
Canada. The Cree people speak the
Algonquin language and have their own
written language.
With a DYNAJET high pressure cleaner and up to 500
bar water pressure, a worker removes the loose stone
from the rock surface.
25
The large scale Eastmain-1 camp has all the conveniences of a small town (PHOTO: SEBJ)
22
After years of dispute over the dam project
in their Reserve at James Bay, several clans
of the Canadian Cree Indians, such as the
Mistissini, the Nemaska and the Waskganish,
agreed to a negotiation compromise between
the provincial government of Québec and
their chieftains in February 2002, after an
agreement was reached among the clan
members in the nine villages of the Reserve.
26
8
PM 3723 GB
According to this agreement, the Cree
people will receive a total of 3.4 billion
Canadian dollars (approximately EUR 2.4
billion) over a period of 50 years as compensation
for the construction of dams at
the Eastmain and Ruppert Rivers, and as
compensation for the flooded areas. The
Cree people want to use the money to
develop the economy, the infrastructure and
living space. The negotiated compromise
was strongly disputed, especially among
the younger members of the clans.
Today, there are around 1 million "First
Nations" or "Inuit" people. The first inhabitants
of Canada are supposed to have reached
the country via a land bridge from Siberia
to Alaska. The first contact between
Europeans and the First Nations people
occurred around 1,000 years ago when
Vikings settled predominantly in Newfoundland.
Due to its rich supply of oil and gas,
Canada is today one of the leading energy
exporters in the world. However, extortionate
amounts are spent on using natural
energy resources in their own country.
Today, Canada has 31.5 million inhabitants
(Germany: 81.5 million) and covers an area
of approximately 10 million km 2 (Germany:
0.357 million km 2 ).
The population density is around 3 people
per km 2 (Germany: 231 inhabitants per km 2 ).
9
PM 3723 GB

Background
New machinery means ideally
equipped to compete
28
AUSTRIAN ARABIAN READY MIX
CONCRETE was newly established in
2004. Two new concrete mixing plants,
50 truck mixers and six Putzmeister truckmounted
concrete pumps imported only a
few months ago make the concrete manufacturer
and pumping service provider
with its modern machinery ideally equipped
to face the rigourous competition in the
United Arab Emirates.
29
10
PM 3723 GB
AUSTRIAN ARABIAN opted for the spacious
area in Jebel Ali, approximately 25 km
South West of Dubai, for its strategically
located site. Construction will begin near
here on a new airport this year and the
island world of Palm Jumeirah off the coast
will not be far away.
Two-shift pumping
The new mixing plants currently produce
approximately 2,000 to 3,000 m 3 of concrete
a day yet they are still operating below
their maximum capacity. Presently, around
50 % of the concrete production is placed
by their own truck-mounted concrete
pumps. The fleet of pumps comprises two
BSF 36.16H and four BSF 42.16H. The
truck-mounted concrete pumps are operated
by two drivers who alternate between
shifts in a similar way to their counterparts
in most of the other pumping
services in the UAE.
27
Khaled Ahmed Abu Shaeerah and Najeeb M. Ashour (right)
in front of a map showing the future island world of Palm
Jumeirah
AUSTRIAN ARABIAN is currently highly
involved in the construction projects on
Palm Jumeirah, e.g. in the concreting of the
motorway bridges linking the trunk of the
palm tree to the mainland. Moreover,
AUSTRIAN ARABIAN is delivering and
pumping greater volumes of concrete on
six other office and apartment towers. The
company plans to purchase two stationary
pumps and stationary booms for each highrise
pumping site in the near future. Since
September 2005 the company belongs to
the ARABTECH group.
Demand for customer training on site
Najeeb M. Ashour, Chief Technical Officer
and Deputy General Manager for AUSTR-
IAN ARABIAN in Dubai, places considerable
value on the qualifications of his
employees, especially of the concrete pump
drivers who may not yet be responsible for
valuable machines but assume a great deal
of responsibility on the construction sites
when operating the pumps and placing
booms. “We are pleased to have our
employees travel to Germany for training,
but we would much prefer it if Putzmeister
could carry out the training here on site,”
remarks Najeeb M.Ashour. This is because
AUSTRIAN ARABIAN cannot cease delivery
operations on the construction sites.
There is never any talk of a “winter break”
or an interruption in work due to periods of
poor weather here in the UAE. At the PM
Academy, Najeeb M. Ashour managed to
win support for his proposal of customer
training in the country itself: two-day
courses covering the topics of engineering,
controls and safety in concrete pumping
and training on how to operate stationary
pumps are expected to be offered in the
UAE from mid-November with the cooperation
of PM agency, GERMAN GULF.
The large construction sites on Palm Jumeirah, which
AUSTRIAN ARABIAN supplies with concrete and on which
the company uses its concrete pumps, also include the slip
roads onto and exits from the feeder road from the mainland
Najeeb M. Ashour in front of one of the new AUSTRIAN
ARABIAN motorway concrete pumps
30 31
Modern mixing facilities even for challenging concrete mixture breakdowns
11
PM 3723 GB

Refurbishment
Not as easy as you think –
Diamant Mühle Hamburg refurbishment
Sometimes its not all that easy to deliver
concrete to where it is needed. For the
refurbishment of the nearly 70 year old
Diamant mill in Hamburg-Wilhelmsburg,
the concrete first had to cover a distance
of about 110 m, for example, before arriving
at the sliding formwork. This was a
real challenge for the team from TBG
Pumpendienst Nord GmbH from Bad
Oldesloe, which relied on a Putzmeister
SANIMA concrete pump and a high
pressure delivery line.
As part of the refurbishment of the
Diamant mill, the 15 silos were concreted
inside the building between February and
September 2005. For each job, the sliding
formworks in three silo cells were each
continuously fed with concrete for approximately
80 to 90 hours. For each of the five
construction sections in total, approximately
300 m 3 of concrete was used. The relatively
long delivery distance and the tight
time frame, which was prescribed by the
stroke speed of the sliding structure, made
particular demands on the concrete. On the
one hand, the material had to be easily
pumpable, and on the other hand, it had to
set quickly. As the concreting work was
carried out both in winter and in the warm
summer months, the concrete supplier
ROBA also adapted the concrete mixture to
the season.
For easier feeding from truck mixers, the 20 m SANIMA boom is slightly raised. At this refurbishment site, the concrete is
delivered by a riser connected to the hopper (Photo: TBG Pumpendienst Nord)
The mill silos were refurbished under the
management of the construction company
WASSMANN + SÖHNE, Burgdorf.
Completion is planned for the end of
December 2005.
33
SANIMA delivers direct to the riser
At this construction site, the distance to be
covered by the concrete before it reaches
the sliding formwork is not run of the mill.
This is because the total length of all three
lines to be fed with concrete was 230 m.
The concrete pump, a Putzmeister SANI-
MA 20.09 S, therefore not only used the
delivery line on the boom, but also pumped
the ready-mixed concrete directly from the
hopper to a connected riser. "We specifically
adapted this delivery line", said Thomas
Göllner, managing director of TBG
Pumpendienst Nord GmbH, "for this property
and mounted it on the exterior walls
of the silo building to be refurbished."
32
The vertical delivery line was carefully mounted on the wall
(Photo: TBG Pumpendienst Nord)
usually already fully equipped with these
additional hoses and pipelines in special
magazines. Several variants can be selected
in the stowage compartments, for example,
TBG-Betonpumpendienst Nord's SANIMA
has up to 150 m of DN 65 hose on board.
A further typical use is illustrated by the
refurbishment works at the Hamburg
Diamant mill.
Here, TBG Betonpumpendienst Nord benefits
from the characteristic advantages of
SANIMA. For example, the compact truckmounted
concrete pump contents itself
with a minimum support extent of just
3.9 m to the front and a support extent of
2.3 m to the rear, meaning it remains within
the vehicle dimensions. In addition, the
machine has an efficient pump aggregate,
which is designed for a concrete pressure
Refurbishment
of up to 112 bar (maximum/theoretical).
The SANIMA is therefore also equipped
for larger delivery distances.
125 mm delivery line reduced to 65 mm
The connected delivery line is a Putzmeister
ZX high pressure line, which can withstand
a concrete pressure of 250 bar. The concrete
was initially pumped 30 m high on the external
wall and then delivered approximately
30 to 40 m to the silo roof. At the end
of the now horizontal line, TBG employees
had fitted a flexible delivery hose, which
was manually switched to one of the three
downpipes leading to the silo cells (length
approximately 30 m each), according to
requirements. Over the entire distance, the
cross section of the delivery line was reduced
from DN 125 to just DN 65. The
riser could easily be closed via a mechanical
guillotine in the pipeline at ground level.
Thomas Göllner said, "This multiple tapering
of the line diameter was a particular
challenge for us, as there was a risk of concrete
jams especially at the tapering points,
and this was to be avoided at all costs in a
line of this length!"
The construction process required close
cooperation by all those involved. For within
each construction section, all processes
had to smoothly mesh within a defined
period of time. For TBG Pumpendienst
Nord, this construction site is also an
example of how specialists can collaborate
to successfully solve a technically
challenging task.
We would like to thank TBG
Betonpumpendienst Nord and Heidelberg
Cement for their support.
35 36
34
12
PM 3723 GB
The SANIMA 20.09 S allows extremely
flexible work, especially in refurbishment
projects. The machine, built on a 2-axis
chassis, has a 20 m high placing boom with
three arm segments in a "Z" fold, whose
working range is often sufficient in smaller
construction sites. If the use of a larger
truck-mounted concrete pump is required
but not possible due to the limited footprint,
the 20 m SANIMA boom can also be
used as a pipe bridge and the missing reach
is compensated for with connected pipelines
or delivery hoses. The SANIMA is
This SANIMA 20.09 S has a 150 m delivery hose
(DN 65) on board
The ZX high pressure line is supported with timber blocks in the area of the guillotine
(Photo: TBG Pumpendienst Nord)
13
PM 3723 GB

Technology
Flexible 20 m "quad" – Universal
truck-mounted concrete pump with
an unfolding height of just 3.9 m
With its new M 20-4 ZR model,
Putzmeister AG has extended its range of
compact truck-mounted concrete pumps
which can be used even in the narrowest
of spaces. What is particularly noticeable
about the machine is the boom which is
folded four times according to the "Z roll
and fold" principle. Previously, this boom
folding type was only used on larger
truck-mounted concrete pumps, e.g. for
the type M 24-4 ZR.
It is easy to tell which concreting tasks the
new M 20-4 "Z roll and fold" was designed
for, with its boom folding principle and
low truck height. Primarily, it is intended
for construction sites which could not previously
be operated with standard truckmounted
concrete pumps. For example,
narrow back yards in residential and
industrial areas as well as rooms that are
lower than 4 m high. The sites in question
also include construction and refurbishment
projects in low buildings, tunnels or underpasses.
Of course, normal construction
sites can also be operated with the folding
boom. For in concreting work in high construction,
the 20 m boom is excellently suitable
as a pipe bridge which – practically
without any loss in vertical reach – can
snake horizontally up to the 6th storey
(usual floor height approximately 2.7 m)
and be fed through windows or other opening,
even the smallest of brickwork openings.
The unfolding height of the new "quad"
M 20 ZR is just 3.9 m. In addition to the
specially developed placing boom, the
newly designed base structure also takes
into account the latest findings from
weight-optimised steel construction. With a
front support extent of just 3.2 m (rear within
the vehicle width of 2.5 m), the compact
truck-mounted concrete pump can be supported
and unfolded in even the narrowest
of passageways. In short – the space required
to support the M 20-4 is not greater than
the area that the machine takes up when the
driver's door is open.
38
"Quintuplet" adapts itself
A large boom pump with a particularly flexible
placing boom was required in the carcass
of the new EL CORTES INGLES
shopping centre in Spanish Castellón. A
wide and deep bottom plate with five basement
floors also had to be concreted, in
addition to the long underground parking
access and the spacious floor areas. Due to
the narrow space conditions around the Old
Town, the position for setting up the
machine had to be considered in great
detail. The contract for placing the concrete
was awarded to the GRUPO TELEBOM-
BEO pump service provider, which used a
new Putzmeister BSF 52.16 H for many
weeks at this construction site.
Building construction
Our photo shows the machine during concrete
placement on the fifth storey after
machine operator Alfredo Muñoz had integrated
100 m 3 of concrete in the underground
parking area of the future shopping
centre a few hours previously. It is easy to
see how the boom of the M 52 "quintuplet"
can adapt to the building structure without
wasting any horizontal reach: first, the "A"
and "B" arms are used to reach the required
building height. Then the length of arms
"C", "D" and "E" is available as a horizontal
working range.
40
37
2,5 m
3,2 m
Our illustration clearly shows the narrow conditions
under which the M 20-4 placing boom can be used
(passageways, back yards, etc.).
The extremely flexible concrete boom has
a 125 mm delivery line as standard, in a
particularly hard-wearing, 2-layer design.
The core pump recommended by
Putzmeister is an aggregate with a 1,400 mm
stroke and 230 mm delivery cylinder Ø,
which is designed for delivery rates of up
to 90 m 3 /h or pump pressure up to 78 bar.
Delivery will begin in spring 2006.
The short wheelbase of just 4.5 m ensures
an extremely small turning circle. With a
permissible gross weight of less than
18 tons for the 2-axis chassis and an actual
tare weight of approximately 15 tons
(depending on the vehicle), the M 20-4
also has significant weight reserves. This
enables the small "quad" to carry additional
hoses and pipes, meaning that the working
range of the machine is significantly
extended.
39
Horizontal reach 16.1 m
Vertical reach 19.5 m
Unfolding height
3.9 m
14
PM 3723 GB
15
PM 3723 GB

Large construction site
42 43
Numerous concrete pumps
at Germany's largest
construction site
Since September 2004, the new Stuttgart
Trade Fair Centre has been under construction
at spellbinding speed, south of
the regional capital of Baden-Württemberg
between the A8 motorway, the B 27 main
road and the airport. Several concrete
pump service providers use their machines
here almost every day. In order to ensure
that concrete placement proceeds as
smoothly as possible, the use of the many
concrete pumps is scheduled centrally.
motorway with direct access roads and
Stuttgart International Airport, which is
within sight of the complex.
The contract for construction of the trade
fair halls, the congress centre and the
underground car park was awarded to the
Rohbau Landesmesse consortium, consisting
of MAX BÖGL and LEONHARD
WEISS. The two partners have also joined
forces to create a civil engineering consortium,
which will construct two bypass tunnels
– one near the airport and one on the
north side of the A8 – as well as a bridge.
The parking decks of the new Stuttgart
Trade Fair Centre stretch across the A8
motorway – here is a model view
(Fig.: Projektgesellschaft Neue Messe)
By its opening in spring 2007, seven standard
halls with an exhibition area of
10,000 m 2 each, a 25,000 m 2 tall building
(headroom of 14 to 24 m), an international
congress centre and a generously proportioned
convention centre will be constructed
here on a total area of 83 hectares.
Optimal transport connections will be
ensured by a planned ICE long distance
and regional train station, an underground
car park beneath the convention centre, the
new multi-storey car park over the A8
Another consortium consisting of WAYSS
& FREYTAG INGENIEURBAU,
BARESEL and DONGES STAHLBAU,
has been awarded the contract for completion
of the new multi-storey car park,
which, at a length of 440 m, spans across
the A8 motorway and a planned new
stretch of ICE track. The total investment
for the new Stuttgart Trade Fair Centre is
estimated at EUR 806 million. The project
is currently considered to be Germany's
biggest construction site.
41
44
A Putzmeister M 52-5 large boom pump during concreting of the foundations
16
PM 3723 GB
Photo: AOP aerial photo
Until recently, the fields on which the new trade fair premises are now being constructed,
were intensively farmed for pointed cabbage – a regional speciality
45
17
PM 3723 GB

Large construction site
46
Up to 1,500 workers are employed on the
vast site. In peak times, 60 cranes lift the
various loads to the different sections. In a
separate production facility, prefabricated
steel parts are supplied, and the necessary
welding and anticorrosion work is carried
out on site.
Two concrete pump centres ensure
smooth placement of 270,000 m 3 of
concrete
In order to guarantee self-supply with concrete,
two mixers have been set up on the
premises. A MAX BÖGL owned system
delivers the Rohbau consortium with
approximately 250,000 m 3 of concrete,
while the concrete produced by the other
mixer is required for the construction of
the multi-storey car park (approximately
20,000 m 3 ) and also covers the peaks in
demand from the Rohbau consortium. The
mixers also produce self-compressing concretes,
in addition to standard concrete with
strength class C40/50.
construction of the interior, the exposed
concrete, with its natural surface structure,
plays an important role and must be pumped
without interruption. To do this, BRM uses
all sizes of truck-mounted concrete pumps
– from a refurbishing mobile through to a
large boom pump. TB Göppingen or BP
Schwaben's machines are also scheduled.
For the concrete work around the multistorey
car park, pump service provider
SAUSSELE (Besigheim), which belongs to
CEMEX, controls the use of concrete
pumps. Here too, it is usually the maintained
machines from their own fleet that are
set up on both sides of the motorway. With
increasing completion of the interior of the
car park levels, the flexible "low building
masters" with 24 m booms with four folds
are most in demand. Other concrete pump
service providers, such as UNION-BETON
(Ludwigsburg) and GODEL-BETON
(Stuttgart) also provide their machines as
required.
A PM M 36 truck-mounted concrete pump filling
a wall formwork
48
According to information from project
manager Dipl.Ing. Michael Frey, the coordination
with the central pump scheduling takes
place fairly smoothly, taking into consideration
the large concrete volumes and the
number of contract sections. He considers
the fact that his consortium only has to coordinate
with one concrete pump schedule as
a great advantage: "Of our ten foremen, each
one works with his people on a separate construction
section.
Often they all need concrete in the afternoon.
Central scheduling is therefore very helpful
if our concrete mixer is constantly fully
loaded and we want to use the pumps with
the required boom reach at the same time at
the individual sections."
Project manager Dipl.Ing. Michael Frey
49
The concrete pump scheduling for the
MAX BÖGL and LEONHARD WEISS
construction sections is carried out by
Betonpumpendienst Rhein-Main (BRM),
Lorsch. The range of concrete work is considerable:
long strip foundations, powerful
bottom plates, floors, girders and circular
supports, external walls and internal
partitions, etc. Above all, in the
47
This M 36 used by the concrete pump service provider
BRM is today encountered on several sections of the
vast trade fair construction site
50
BRM operator
Werner Mann. He
has been operating
51
concrete pumps for
13 years
Our picture shows one of BP Schwaben's BSF 52.16 H
pumps on field 2 during the placement of 280 m 3 of
concrete. As soon as the bottom plate is completely concreted,
the machine is moved by a few hundred metres,
in order to pump 400 m 3 of concrete into a ceiling formwork.
18
PM 3723 GB
A BSF 28.16 H with refurbishment equipment
19
PM 3723 GB

Background
High quality requirements even in the
construction of model concrete pumps
54
Background
55
These are gifts with which you can give
particular pleasure to business partners.
Some people have even collected their
exhibits, sometimes over the course of
many years, with great commitment –
above all of a financial nature. We are
talking about miniature construction
machines, which are produced to scale by
highly specialised manufacturers, such as
CONRAD GmbH (Kalchreuth).
Putzmeister too has been buying the different
models of its truck-mounted concrete
pumps since the 70s, and also the TELE-
BELT telescopic deliverer, as models produced
to a scale of 1:50 from the Franconian
specialist. A larger model scale of 1:35 has
been chosen for the PM plastering machines
and floor screed conveyors – let's not
forget the machines are actually significantly
smaller in real life. The decision to order
a model of a concrete pump with the new
placing boom, for example, must be well
thought out. For, in addition to the later
unit costs, the customer often also has to
cover the costs for the handmade model,
that is, for the prototype, as well as for the
construction of the mould.
Before the new models can be produced,
an accurate manually produced specimen
must be created. To do this, the dimensions
of the original are converted to scale, the
52
required material strengths are calculated
and the mobility – e.g. the composition of
a multi-part concrete boom – is simulated.
The handmade model is also used as a
pattern for the construction of the model
and for the subsequent mould construction.
Modern CAD/CAM computer systems and
CNC milling machines play an important
role in conveying the fine contours.
As with the "real" construction machines,
CONRAD uses metal (zinc) and highquality
plastic for its models. The relatively
heavy zinc is not only easy to handle in
liquid form, but its weight also gives the
finished model part of the "valency" and
"mass" of the actual original. The plastic
and the zinc are both pressed in injection
moulds in which the respective components
are given their later, often filigree
structure. Several components are held by
one mould carrier. The zinc is pressed at a
pressure of up to 150 t/cm 2 .
After the mould carriers are automatically
ejected from the injection moulding machines,
CONRAD employees carefully check
the individual parts. The edges are filed by
machine, but the grinding and polishing is
still often manual work. The entire production
process is organised to the last detail.
As with the original, the visual impression
of the product also plays an important role
in model construction. This includes a
smooth, notch-free surface as well as careful
painting. At CONRAD, the same undercoat
and topcoat paint is used as in the
automotive industry. The paint is applied in
up to six stages. As the colour tone of the
components consisting of different materials
must be the same, different paint compositions
are used for colouration of the
plastic components and the cast zinc parts.
A CONRAD employee operating the injection moulding
machine
53
Even the latest PM models are produced
with attention to detail.
The picture shows the SIKA-PM 500 shotcrete device
as well as the high pressure BSA 14000 HP-D
concrete pump
CONRAD was founded in 1956 and began
producing faithful model vehicles in 1971.
Today, the company presents itself as the
leading manufacturer of model vehicles,
with modern prototype and mould construction,
a pressure casting foundry, plastic
injection moulding, an environmentally
friendly painting system and a department
for screen printing. Due to the good collaboration
they have experienced over decades,
Putzmeister AG has also arranged to have
its new models, such as the BSA 14000 HP
concrete pump and the SIKA-PM 500
shotcrete device manufactured by
CONRAD GmbH.
56
57
Mould carriers with parts of the stationary pump model
The zinc raw material is delivered to model builder
CONRAD in bars
The two halves of an injection mould for the BSA model
20
PM 3723 GB
21
PM 3723 GB

Special concrete
The ZX delivery line in the lattice tower of the
crane runs to the sliding formwork
New platinum mine
in South Africa:
concrete placement on
109 m high pit frame
58
60
Platinum and its costly mining
Platinum is currently almost twice as expensive
as gold, and significantly harder.
World-wide, only approximately 200 tons
of this precious metal are mined each year,
with 90 % of the production stemming
from South African mines. Platinum is
required, for example, for the production
of catalytic converters in the automotive
industry, in dental medicine, in space travel
and for the production of jewellery. To
acquire 15 grams of pure platinum, up to
five tons of stone must be exploded, conveyed,
pulverised and chemically treated.
The metal is prepared above ground in
high security areas. The platinum discovery
sites around the Rustenburg region
were mined in a strip of approximately
400 km. Here, 27,000 miners work under
the hardest of conditions at depths of
approximately 2,000 m. With an air humidity
of 90 %, there are temperatures at this
depth of up to 50 °C. The platinum reserves
were discovered in 1924 by the German
geologist Hans Merensky. The land rights
in Rustenburg belong to the Bafokeng
clan, to which the IMPALA PLATINUM
group assigns 5 % of its profit each year
as payment for rights of use.
In Rustenburg in South Africa, the
IMPALA PLATINUM LTD mining company
is investing significant sums of
money in the mining of the precious metal
platinum. In the meantime, work is being
carried out on the completion of the 16th
shaft. Already before commissioning,
Putzmeister pumps were used here,
although not for pumping residues from
the ore dressing (tailings), but for highrise
concrete pumping.
In addition to constructing the shaft and
connecting a new mining field to the existing
mining fields, the tapping of a new
mine also includes the installation of a pit
frame. At its tip, the pit rope, to which the
haulage skips for bringing up the mined
material and the baskets for transporting
the miners are attached, runs over a large
pulley. In order to move the largest loads
possible, or to achieve short circulation
times, the pit frame must be of a certain
height. At the 16th pit of IMPALA in
Rustenburg, the tower is certainly not too
small: with a base of 21 m x 20 m and a
pulley at the record height of 109 m, the
new pit is designed for extraordinary conveying
capacities.
A sliding formwork adapts to different
wall thicknesses
The work on the pit frame with several
integrated concrete decks began with the
pit brow at a depth of approximately 25 m.
The main contractor assigned with the
construction work is RENNIKS CON-
STRUCTION. The project, costing around
80 million rand (approximately EUR 10
million), also includes the construction of
the main ventilation shaft, several access
tunnels, the foundation of the conveying
system and various digging works.
Completion is planned for May 2006.
The walls of the pit frame, which are
between 0.95 m and 0.55 m thick, were
constructed using the sliding formwork
procedure. Here, the formwork adapted
22
PM 3723 GB
Truck mixers load the BSA 1408 E with a special type of concrete
59
In total, approximately 21,000 m 3 of concrete are processed
at the pit frame
62
The PM gate valves are activated via a hydraulic circuit
in the stationary pump
61
flexibly to the wall diameter which becomes
thinner as you move upwards. The contract
for concrete delivery was awarded to the
specialists from MURRAY & ROBERTS
CONSTRUCTION, who, incidentally, have
been working with Putzmeister pumps for
many years.
In total, 7,000 m 3 of concrete was required
to construct the carcass of the pit frame.
The concrete used had a specially developed
mixture breakdown. It contained,
amongst other things, aggregate with a
maximum particle size of 19 mm (of which
50 % was slag), drift sand, stone dust and
various concrete additives. The further
details of the concrete composition are
considered to be confidential. In other construction
measures within the project, a
further 14,000 m 3 of concrete was placed.
The "chief operator" has full control of his Putzmeister
stationary pump. On the left you can see the cable
remote control of the BSA 1408 E
63
BSA and rotary distributors
work as a team
The free-pumping material was delivered
by MURRAY & ROBERTS with a
Putzmeister BSA 1408 E via a ZX high
pressure line, which was mounted on a
tower crane. With a hydraulically activated
gate valve, the concrete flow in the pipeline
could be interrupted, for example for cleaning
operations on the stationary pump.
A second BSA was kept ready as a standby
pump. The crane was set up about three
metres from the carcass and mounted with
cross-beams in the continuously rising
structure. The upper end of the riser was
connected with a flexible hose (DN 125),
so that a connection to the RV 10 rotary
distributor on the sliding formwork could
be established at any time in the 90 ° delivery
line bend. Incidentally, this too was a
device manufactured by the Putzmeister
subsidiary in South Africa. In the interest
of the most unrestricted slewing circle
possible, the construction company elevated
the four support legs of the deck distributor
by approximately 5 m.
Service technicians available at all times
During the carcass construction phase,
employees of Putzmeister South Africa
were on site at least once a week. They
trained the concrete pump operators, gave
tips on cleaning and maintenance of the
BSA and clarified any service questions.
In addition, the PMSA emergency service
was also available 24/7 via a hotline.
A service technician could have been on
site within 2 hours, if required.
As the construction progressed, additional
pipe sections were used between the riser
and the delivery hose. On average, the pit
frame grew by 4.5 m each day, with the
best daily performance being 6 m. At
109 m, the BSA 1408-E reached its highest
pump height on the new IMPALA pit.
23
PM 3723 GB

Background
Building construction
Ten in
a row
For decades, Putzmeister concrete, mortar
and high density solids pumps have been
used in Japan, a country which is spoilt
for technology. Of course, it takes quite a
bit longer to transport the machines to the
Far East, and the transport process is
associated with significantly higher costs
for PM dispatch. The simultaneous shipment
of ten truck-mounted concrete
pumps on the 21,000 km long ocean
voyage to Tokyo at the end of October was
the exception to the rule but, at the same
time, was a fascinating example of the
careful planning and smooth cooperation
between all those involved.
24 October: From 3.30 pm, six truckmounted
M 28 concrete pumps and four
M 36 machines are standing in two rows of
five, ready for departure, on PM's company
premises. The drivers from GERBER
Transfer und Logistik, to whom the shipping
company FR.MEYERS’S SOHN
INTERNATIONAL LOGISTICS GmbH
has assigned the contract to transport the
ten right-hand drive truck-mounted concrete
pumps to Bremerhaven, are ready to go,
now that each of them has checked that the
tyre pressure and the oil and coolant levels
in the vehicles entrusted to their care are
ok. They set off in convoy towards the
north, with a good 700 km motorway or
nine hours of pure driving time ahead of
them. The next morning, the transport
drivers hand the concrete pumps over to
BLG Automobile Logistics GmbH, a company
in Bremerhaven which has specialised
in loading and unloading freight ships.
64
At about 7.30 am, they begin loading the
PM truck-mounted concrete pumps. In
groups of two and three, they are driven
from the assembly site which is 600 m
away, across a relatively flat bow ramp
onto the main deck of the "Hual Tokyo".
The drivers appear to be able to move
anything that has more than four wheels:
200 ton mining trucks for strip mining,
heavy mobile cranes, road cutters, track
vehicles or even truck-mounted concrete
pumps – everything has to be positioned in
the narrowest of spaces and lashed securely.
The total of around 150 trucks and heavy
commercial vehicles are relatively quickly
accommodated on board, with the loading
of almost 2,500 passenger cars lasting
through to the evening. At around 11 pm,
the "Hual Tokyo" departs. The journey will
take it via Southampton and Le Havre
through the Mediterranean and into the
Suez Canal. After stops in Singapore, Hong
Kong and Taiwan, the floating vehicle
transporter is expected in Toyohashi
Harbour (near Tokyo) on 28th November.
Six M 28 and four M 36 stand on PM's company premises,
ready to depart on their journey to Japan
Long sea route to Japan
The "Hual Tokyo", commissioned in
2004, was designed as a RoRo freight
ship, i.e. the ship only takes truckmounted
freight on board ("roll on/roll
off"). The ship, with a displacement of
57,280 gross register tons, sails under
the Norwegian flag and measures
approximately 32 m across and 199 m
in length. On its twelve decks, the
"Hual Tokyo" has an area of approximately
54,300 m 2 , space enough for
6,100 passenger cars. The crew of 24
is accommodated in single cabins and
is predominantly made up of
Philippinos.
The direct sea route from Bremerhaven
to Toyohashi in Japan is approximately
11,400 nautical miles, which
corresponds to around 21,100 km.
However, the transport route is longer,
due to the five intermediate stops.
Nonetheless, the "Hual Tokyo" scarcely
needs more than four weeks sailing
time. At an average speed of 20 knots
(37 km/h), the fuel consumption
(heavy oil) is approximately 60,000 l
per day (2,500 l/hour). The freight
costs for a 30 metre long truck-mounted
concrete pump are approximately
EUR 7,000.
65
Between sun and sea
Some call it a "holiday factory", others
are happy that there are still holiday
homes in which entire families can spend
their vacation relatively cheaply. We are
of course talking about the Spanish
tourism stronghold of Benidorm on the
Costa Blanca.
The mild climate in the area means that the
holiday season lasts all year. For more than
40 years, the former fishing town of
Benidorm has lived in high style for and as
a result of tourism. The town has 130
hotels with nearly 40,000 beds, as well as
around 200,000 holiday apartments. Over
an area of 18 km 2 , there are 150 high-rise
buildings, including four of the ten highest
buildings in Spain.
As our picture shows, construction work is
still going on. At present, EDIFESA is building
two high-rise apartment blocks and four
underground car parks. Compared with the
210 m tall Gran Hotel Bali (52 storeys), the
modern residential towers, with "just" 20
storeys, almost blend into their surroundings.
As is usual in Spain, only relatively
little concrete is required to fill the floors,
due to the use of the cavity stone construction
method. At this construction site, for
example, only about 100 m 3 of concrete are
required per storey. This concrete is a C30
with aggregates of broken material and a
maximum particle size of 12 mm. The concrete
is delivered through 2-layer pipelines
with a stationary Putzmeister BSA 2109 H-D
concrete pump. Señora Claudia Fernandez
monitors the correct composition of the
concrete batches on the construction site.
A BSA 2109 H-D during concrete delivery on the
Spanish Mediterranean coast
66
26 October: Loading of the 200 m long
"Hual Tokyo" begins at 6.30 am. The RoRo
freight ship, specially designed for transporting
vehicles, has just docked a few hours
ago after arriving from Newcastle in
England. While high-quality passenger
vehicles by famous manufacturers from
Munich, Augsburg and Stuttgart disappear
into the huge ship in dozens and, depending
on the port of destination, are driven onto
different decks, the teams are still also
busy clearing the freight intended for
Bremerhaven.
24
PM 3723 GB
At the crack of dawn, the truck-mounted concrete pumps are driven on board the special transporter together with
150 other commercial vehicles and 2,500 passenger cars
25
PM 3723 GB

Special concrete
Large boom concrete pumps inject
"Bügelbauten" bookend buildings
With the completion of the two 46 m tall
office towers, the last construction section
of the new Berlin main train station
began at the end of July 2005. The imposing
building is being constructed on the
site of the former Lehrter train station
and, after completion, will be used as the
central terminal for north/south and
east/west rail transport in the German
capital. According to forecasts, 300,000
passengers and visitors are expected at the
Lehrter train station each day.
The pump service provider LICHTNER
used three Putzmeister concrete pumps to
inject the complicated floor structure of
steel sections with a specially developed
concrete, as well as to concrete the floors.
68 69
Berlin's first main train station
As in London and Paris, Berlin never
had a central main train station in the
past. Due to the star-shaped railway
network, the railway lines ended at the
edge of the capital city. At the end of
the 19th century, a suburban railway
line connected the city's most important
long-distance train stations.
The old Lehrter train station, opened in
1871, was severely damaged in the
Second World War, and the ruins of the
former building were blasted at the end
of the 50s. Thereafter, the Berlin suburban
railway used the site as a stopping
point. After the fall of the Berlin
wall, intensive work went into plans
for a central traffic node for the
German capital city. In 1998, work on
the new train station began.
At the end of May 2006, shortly before
the Football World Cup, the Lehrter
train station is to be officially opened
as "Europe's most modern train terminal"
– according to DEUTSCHE
BAHN AG.
The aboveground part of the new Berlin
main train station (east/west direction) has
four platforms for long-distance and regional
trains and two platforms for suburban
railway traffic, 10 m above street level. For
the north/south connection, eight platforms
for long-distance and regional trains as
well as two for the underground line U5
will be constructed 15 m below ground.
A huge glass roof with a length of 321 m,
which is installed above the east/west
wing, will act as protection against bad
weather and will allow daylight to reach
even the deeper floors.
The critical section of the project is the
completion of the bookend buildings. These
are two 46 m tall office buildings which, at
a length of 87 m, straddle the east-west line
like bridges at the intersection of the railway.
The two twelve storey buildings were
initially constructed as four vertical tower
halves, which were tilted by 90° in summer
2005 and welded. This procedure, which is
not carried out every day, was chosen to ensure
that the railway traffic flowing beneath
the buildings did not have to experience
disruption caused by a long construction
period.
The carcass construction work for the solid
structure of the bookend buildings was
carried out by WAYSS & FREYTAG
INGENIEURBAU AG.
Highly effective deflocculant helps the
concrete spread into "dead angles"
The four bookend buildings consist of
numerous steel pipe sections which are
designed as loadbearing composite constructions.
26
PM 3723 GB
Lowering of the bookend buildings over the east/west line of the Lehrter train station (Photo: DB AG/Reiche)
Even in the narrowest of spaces, the two
Putzmeister M 42 and M 52 can be set up by
the concrete pump service provider LICHTNER
– as shown here for concreting the floors
67
Amongst other things, the pylons, the
external and internal supports of the bases
of the bookend buildings and the lattice
girders of the four 1,250 ton bookend halves
with their numerous upper, middle and
lower flanges were injected with concrete.
The contract for this work was awarded to
LICHTNER pump service provider from
Velten, which, over a period of months,
used its Putzmeister truck-mounted
BSF 36.16 HLS, BSF 42.16 H and
BSF 52.16 H concrete pumps for the work.
The steel sections contain a very densely
set reinforcement and, up to a height of
10 m, are injected with a specially developed
concrete with strength class C45/55 in
one operation. The mixture breakdown
includes an increased fines content and a
highly effective plasticising admixture
based on polycarboxylatether (PCE), which
displays an even higher deflocculation
effect compared with the familiar super
deflocculants. As the pumped concrete contains
practically no more air particles, and
has a very free-flowing consistency (F5 to
F6), additional shaking is not necessary.
Injection through 150 m long 65 mm
delivery hose
At the start of the injection work, the boom
length of the BSF 36.16 HLS was still
sufficient. As the construction progressed,
however, LICHTNER started to use its
concrete pumps with 42 and 52 metre
vertical reach. In order to also be able to
Up to three concrete pumps simultaneously inject the numerous
steel sections of the bookend buildings. Picture shows M 36.
reach the farther removed filler pipes, a
tapering, which reduced the line diameter
to 65 mm, was connected to the machine's
boom tip instead of an end hose. The
connection of up to 150 metres of hose
meant a significantly increased working
range could be achieved. As expected, the
hydraulic pressure of the pumps increased,
but remained within a reasonable limit.
Filler pipes situated beneath the steel sections
fill them with quantities of 5 to 6 m 3 .
The slow ascent of the concrete in the constructional
element discharges the available
air upwards. The filler pipes in the injected
steel sections are closed with guillotines
and concrete is prevented from escaping by
cutting the line. Injection of the bookend
buildings started in April 2005 and completion
is planned for the end of 2005.
In addition to injecting the steel sections
with special concrete, the two LICHTNER
large boom pumps BSF 42.16 H and
BSF 52.16 H are also used for concreting
the floors. Their boom length means they
can also reach higher levels of the bookend
buildings. To do this, the large boom
pumps need a C 40/50 concrete with a
maximum particle size of 16 mm, and the
individual sections each hold approximately
120 m 3 . For this work too, the pipe at the
boom tip of the truck-mounted concrete
pump was reduced to 65 mm diameter
through the addition of a tapering and a
flexible hose with a length of up to 30 m
was connected.
The floors are concreted with the boom tip extended
and with a 65 mm delivery hose attached
Guillotines are used to close the steel sections after
injection
70
71
27
PM 3723 GB

Application
Concreting
on water
Imprint:
Publisher
Putzmeister AG
Max-Eyth-Str. 10
D-72631 Aichtal
Tel.+49 (71 27) 599-0
Fax 599-520
■ Editor:
Jürgen Kronenberg
■ Design:
Friedrich Pippich
Putzmeister AG, Max-Eyth-Str. 10, D-72631 Aichtal
PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458
This picture shows how you can set up an
efficient concreting unit for underwater
concrete work in the smallest of spaces.
The six machines consisted of four truck
mixer swap bodies with independent power
unit, a stationary concrete pump and a
stationary Putzmeister MX 24 boom on a
tubular column. Our picture does not reveal
the location of the stationary pump, which
is between the four truck mixer swap
bodies and was fed via chutes from the
mixers. The concrete was delivered via a
short pump line to the stationary boom
(here still the older "triplet" version with
roll-and-fold system). To fill the mixer
drums, each with a capacity of 7 m 3 , the
pontoon was pulled to the "short line" by
two small tugs and towed to the harbour
quay. There, the "correct" truck mixers
were waiting to handover the ready-mixed
concrete.
72
Your fax for further information
■ Would you like more information on certain topics in this edition of Putzmeister Post?
If so, just copy this page, make a cross next to the topics you are interested in and fax
the form to us. We will then send you detailed information immediately.
❏ Delivery line systems ............................................................................PM 2300
❏ Stationary concrete pumps ....................................................................BP 2632
❏ Economic concrete distribution with stationary booms..........................MT 2059
❏ TELEBELT Telescopic belt conveyor TB 105 ..........................................TB 2409
❏ DYNAJET-High Pressure Cleaners ......................................................MM 3464
❏ Truck-mounted concrete pump M 20-4 „Z“............................................BP 3697
❏ Truck-mounted concrete pump M 52-5 „Multi-Z“ ................................MT 3231
❏ Truck-mounted concrete pump M 36-4 „Z“............................................BP 3180
❏ Truck-mounted concrete pump M 28-4 ................................................MT 2634
❏ Truck-mounted concrete pump SANIMA 20.09 S ..................................BP 2765
❏ Truck-mounted concrete pump M 42-4 „R“ ..........................................MT 2391
Name ........................................................................................................
Company ..................................................................................................
Position ....................................................................................................
Street ........................................................................................................
Post code/City ..........................................................................................
Tel. no. ......................................................................................................
E-Mail........................................................................................................
Putzmeister AG
Max-Eyth-Str. 10 · D-72631 Aichtal
P.O.Box 21 52 · D-72629 Aichtal
Tel. +49 (71 27) 599-0
Fax +49 (71 27) 599-520
Internet: http://www.putzmeister.de
E-mail: pmw@pmw.de
PM 3723 GB
All rights reserved. Subject to technical amendments without notice. The illustrations in some cases show special-purpose machine designs and snapshots of site
practice which do not always comply with the regulations determined by professional bodies. © 2005 by Putzmeister Printed in Germany (3.50512RR)