Dancing Towers on Hamburg's Reeperbahn - Putzmeister

Post
The magazine by Putzmeister Concrete Pumps GmbH 9
The world‘s biggest
stationary boom
on the Bosporus
M 6 placing concrete for
oil production platform in
Russia‘s Far East
Hoover Dam Bypass
Bridge – concreting at a
height of 4 m above
the Colorado River
<strong>Dancing</strong> <strong>Towers</strong> on
Hamburg‘s Reeperbahn
– three long-reach boom
pumps work in perfect
coordination
PM 4307 GB
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Content Content / worth knowing
Title story
Hamburg: <strong>Dancing</strong> <strong>Towers</strong>
Three M 52 long-reach boom pumps used for the concreting
of the foundation slab of the new St. Pauli landmark 4
On site
Hoover Dam Bypass Bridge – the story of a “modern marvel”
Concreting at a height of 274 m above the Colorado River 10
Russia: M 6 placing concrete for oil production platform
„A single one-way ticket on the Trans-Siberian Railway
from Moscow to Vladivostok“ 14
Turkey: The MXKD 50, the world‘s biggest stationary boom
Sensational find from ancient Constantinople – Port of
Theodosius discovered at the underground station in Yenikapı 18
50 questions
How does Putzmeister manage to be so ubiquitous?
In each edition of PM Post we answer one of 50 interesting
questions from the last 50 years of Putzmeister 16
In brief
Putzmeister Academy – Seminar brochure for 2011 1
Launching of the first dredger in China equipped with
a Putzmeister KOS 25100 high-density solids pump 1
Putzmeister at construction sites in India
Worth knowing
Exhibition dates / Interesting facts
Photo credits
Imprint
4 14
Photo credits:
On the Reeperbahn
at six in the morning…
18
History lesson:
concreting at the
Port of Theodosius
Unless indicated otherwise, all illustrations are copyright
Putzmeister Concrete Pumps GmbH.
18: www.datenland.de · 22: hoover_dam_nevada_luftaufnahme,
Wikimedia Commons, licensed under CreativeCommons
license by-sa-3.0, Florian Arnd · 26:
sea_of_okhotsk_map, Wikimedia Commons, licensed
under CreativeCommons license by-sa-3.0, Norman Einstein
· 27: cape tihii, Wikimedia Commons, Vihljun · 28:
nivkh_men, Wikimedia Commons · 29: yuzhno sakhalin
museum (5), Wikimedia Commons, licensed under CreativeCommons
license by-sa-3.0, Straitgate · 30: zametny
island, Wikimedia Commons, Vihljun · 35: istanbul rapid
transit map, Wikimedia Commons, licensed under CreativeCommons
license by-sa-2.5, Maximilian Dörrbecker
10
Imprint:
PM 4307 GB PM 4307 GB
Dizzying heights:
Hoover Dam Bypass
Editor:
Putzmeister Concrete Pumps GmbH
Max-Eyth-Str. 10
72631 Aichtal · Germany
Editorial department:
Volker Wehner, Petra Montag
Putzmeister Concrete Pumps GmbH
Layout/DTP: Petra Montag
Putzmeister Concrete Pumps GmbH
Print:
Offizin Scheufele GmbH & Co. KG
Tränkestr. 17
70597 Stuttgart · Deutschland
2 3
M 6 : 9,000 km
rail journey to the
Sea of Japan
4 5
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 external 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 Concrete Pumps GmbH
2010 · Printed in Germany (3.51009)
Exhibition
dates
October – December 010
04. – 08.10.2010
Elektra Mining, Johannesburg/SA
27. – 30.10.2010
SAIE Bologna/Italy
22. – 25.11.2010
Big 5 Show, Dubai/UAE
23. – 26.11.2010
Bauma China, Shanghai/China
By the
way…
Did you know that for many years
now, Putzmeister delivery cylinders
have been hard chrome plated?
As standard!
This is an important quality feature
and extends the service life
substantially.
6
worth
know
ing

Title story
“Two new dancers on
Hamburg‘s Reeperbahn”
Following the plans of architects Bothe
Richter Teherani, the “<strong>Dancing</strong> <strong>Towers</strong>”
project was begun in September 009
quite close to the Port of Hamburg. On
the approx. 5,400 m² plot at no. 1 Reeperbahn,
two pitched high-rise buildings
and a hotel complex are being built for
around € 150 million. The contractor is
Strabag Real Estate GmbH.
Pump
1 OSS
Pump Full support,
feeding by two truck
mixers at same time
(One side support),
180° forwards
working area
May 010 saw the second phase of concreting
the ground level with a volume of
,650 m³ of concrete. PM has had a look
over the shoulders of those involved,
who own four Putzmeister long-reach
boom pumps (three in use plus one on
stand-by) of the BSF 5 . 0 H type provided
by betonlift GmbH & Co. KG.
Placing such a large amount of concrete
on a single day, even for the old hands of
construction fi rm Ed. Züblin AG, requires
some preparation in planning and consultation
with the contractors. The concrete
supplier is Holcim Beton & Zuschlagstoffe
GmbH (Hamburg), the pumps are provided
by betonlift GmbH & Co. KG and Sociedade
de Construções, Lda (Lisbon) is responsible
for placing the concrete. On this day, 5th
May, work starts with the concreting concept
for the bottom plate, which is subdivided
into six concreting sections. The following
marginal conditions apply:
• Max. plant capacity: 200 m³/h
(four mobile concrete plants, each
with 50 m³/h)
• Setting up three concrete pumps
• Having three construction crews at the
ready
The site management prepares the concreting
plan for each concreting operation.
Pump OSS (One side support),
180° forwards
working area
Concrete Technology
In the case of the second phase described
here, three different types of C30/37 concrete
are used. For the lower part of the fl oor
and the diagonals, the maximum particle
size is reduced to 16 mm because of the high
density of the reinforcement (see the box).
This ensures that the steel is coated with
concrete on all sides. In the middle lay ers,
the maximum particle size is 32 mm, and for
the top layer, it is reduced to 16 mm again.
From the point of view of concrete technology,
it is important to place the individual
layers in such a way that concreting is always
carried out before the bulk concrete
of the previously placed layer begins to set.
This means that the bottom layer must still
be processible when the next layer is being
poured.
Mixture breakdown for the bottom plate bulk concrete
Fresh concrete properties
The concreted section has a surface area
of 24.5 m x 42 m. For a concreting height
of 0.5 m, the concreting volume is approx.
330 m³ per layer with a maximum component
thickness of 4.52 m (1.5 m in the
boundary areas) for the bottom layers. If
one assumes an average output of 150
m³/h, approx. two to three hours will
be required for concreting each layer.
For the upper area, up to 550 m³ per
layer and three to four hours workability
time are set aside. This means that
the workability time for the concrete
supplied for the lower layers must be
slowed to four hours, and fi ve hours
for the upper layers – even once any
change in location of the pumps has
been taken into account.
bottom area middle area upper area
Consistency F5 (58 ± 2 cm) F5 (55 ± 2 cm) F4 (53 ± 2 cm)
Workability time up to 6 hrs up to 10 hrs up to 2 hrs
Hardened concrete properties
betonlift
Service truck
with „caboose“
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Property class C 30/37 C 30/37 C 30/37
Exposure classes XC2, XC3 XC2, XC3 XC3, XD1
Title story
Stand-by pump
8
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Title story
p For some in St. Pauli, this early hour means hometime, but for the workers on the construction site, the day is only just starting:
At half past 5 sharp, the first truck mixers arrive.
Placing concrete - from a practical
viewpoint
Laughing when asked what the greatest
challenge for placing concrete is, project
lead Silke Pförtner from Ed. Züblin AG answers:
“When you see the depth of the pit, the
type of pit lining and the size of the area set
aside for the construction site equipment,
it soon becomes clear: There isn‘t actually
any space for large machines. In addition,
the hours allowed for concreting are clearly
delimited because we have to respect our
neighbours, and therefore we need as many
pumps as possible. So we have teamed up
with betonlift to develop a very target-oriented,
fair, good and safe solution. Because
when placing large amounts of concrete as
you see today, we really can‘t leave anything
to chance. So, for example, we worked with
betonlift to determine first of all the locations
of the three pumps (see fig. 7 and 9),
restricted as we were by a very small set-up
area, the maximum load on the supporting
ground at the edge of the pit, and the access
options for the truck mixers.”
q Don‘t push: Each truck mixer in the
convoy is guided to the appropriate
pump by the signaller.
Pump (far left) has a somewhat larger
set-up area and can be fed by two truck
mixers at the same time.
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Franz Syrowatka from betonlift Hamburg
adds: “To us it was clear that we would be
using our Putzmeister 52 m booms; three in
action and one as a stand-by pump with one
machine operator to relieve colleagues during
the day. The important thing for pumps
1 and 3 was the one side support, and that
we have a working area of 180°. This was
the only way that we were able to reach all
corners of the area to be concreted. With
pump 2, we had somewhat more space. We
were able to provide full support there, and
were able to load using two truck mixers at
the same time. This enabled the P2 to reach
a somewhat higher effective pumping rate
per hour.”
An average pouring rate of 180 m³/h was
assumed for the three pumps combined. At
2,650 m³, this meant a pumping duration of
approx. 14 hours. Therefore, concreting was
set to begin early, at 6:00 am. To save some
Title story
p Keeping an overview: Three booms, moving construction site cranes, constant changing of truck mixers – the construction site
requires the utmost attentiveness from the machine operators.
11 13
time, the four concrete pumps were moved
into place the evening before, which meant
that all that remained to be done was to
set up the machine supports and move the
boom into its working position anytime from
5:00 am onwards. Around 5:30 am, the first
Holcim truck mixer arrived from the plant
approx. 15 km away, and shortly after 6:00
am, the first concrete started to flow. In total,
there were 45 truck mixers constantly driving
to and fro, transporting the concrete to
the “<strong>Dancing</strong> <strong>Towers</strong>”.
t A fence reduces the street width
by half: On one side, traffic can pass
by unhindered, and on the other, the
truck mixers control the M 5 , which
is supported on one side. The one side
support (OSS) for pumps 1 and was
crucial for their use in the tight space
available.
12

Title story
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15
Concreting within tight reinforcement
Because in this area for concreting alone the
reinforcement consisted of 776 t of steel,
the meshing structure was so dense that
specially marked concreting openings (d
= 0.2 m) were planned in a 10 m x 10 m
grid for inserting the end hoses (see fi g. 14).
This allowed the boom to be mainly moved
from point to point at lengthy intervals. However,
the machine operators could not take
their eyes off the ball for a moment, because
the interruptions caused by the frequent
changes of truck mixers had to be agreed
with the concreting team. In addition, the
machine operators also had to keep the other
placing booms and cranes within view, as
they were moving at the same time. Not an
easy job, when you consider that on this particular
day, work started around 4:00 am in
the depot at betonlift, and that the construction
site had special permission to work until
11:00 pm, to be on the safe side.
Top planning combined with a good
working atmosphere produces a high
level of effi ciency
The working atmosphere and level of cooperation
on the construction site were remarkably
good. Contributing to this are very
good organisation of processes and certainly
the mobile combination of workshop and
“caboose”, which Jürgen Bitsch from betonlift
Hamburg sends to the construction site
to supply the team for such large-scale operations
(see fi g. 17). His explanation sounds
quite simple:
“When you require a lot from your team, you
also have to provide some relief for them.
And when you experience what the machine
operators and many others have to put up
with on the construction site, in cold and wet
weather, then it quickly becomes clear that
they really value a cup of coffee or a bowl of
hot stew. It motivates them and refuels them
p Because of the extremely dense
network of reinforcements, the workers
can only feed in the end hose at the
specially marked points.
t Working in the supporting ground:
Zucotec workers are inside the reinforcements
while the bottom layer is
being concreted.
for the next round of work. And because every
construction site worker is welcome, we
have a good reputation. It helps us particularly
when, being far from home, there are
problems from time to time. For example, a
locksmith can be on hand quickly if necessary,
or people who can help to clear out a pipe
fast if there is a blockage. In my opinion, we
get back many times what we‘ve put in.”
Guten Appetit, or is that Bom Apetite?
The same must surely apply to the men
from Zucotec, mostly Portuguese, who were
responsible for placing the concrete inside
the reinforcements, spreading it, venting
and smoothing it. As a spicy aroma begins to
waft across the pit around the middle of the
day, we cram into one of the site containers
in search of the chef, who proudly presents
two trays of fried chicken for his fellow Portuguese
countrymen (see fi g. 16).
At around 9:30 pm, the last Holcim truck mixer
has been emptied, and even all 2,650 m³
of the top layer of fl oor concrete, with its target
consistency of F5, has been successfully
placed. All that remained was smoothing,
tidying up and cleaning. And when PM asked
again the following day how the collaboration
went, project lead Silke Pförtner and
Franz Syrowatka from betonlift agreed: “The
work was hard but was shared equally and
ran smoothly.” ■
© www.datenland.de
‚ The <strong>Dancing</strong> <strong>Towers</strong>
of St. Pauli
Soon to reach up to 85 m in height, the
pitched “<strong>Dancing</strong> <strong>Towers</strong>” have already
become the new symbol of the St. Pauli
district. Combined with the inclinations
in the buildings‘ structure, nocturnal illumination
is meant to make it look as
though the towers are dancing.
In addition to offi ces and a hotel, the
“Mojo Club” will return to its former
address of No.1 Reeperbahn. From 1993
it was an internationally renowned attention
in the nightlife scene of St. Pauli.
The towers are due for completion in
summer 2012.
Webcam at the No.1 Reeperbahn
construction site:
‚ http://baustelle.strabag.at
(various construction sites can be
viewed)
Spectacular construction projects by
architects Bothe Richter Teherani:
‚ www.brt.de
Always worth a visit –
the Hanseatic city of Hamburg
‚ www.hamburg.de
t An army marches on its stomach:
A hearty stew with sausages from the
“betonlift canteen” and Portuguese
fried chicken “à la Zucotec” provide new
strength.
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Title story
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On site On site
The making of a
“Modern Marvel”
[Putzmeister America, October 2009]
The Mike O‘Callaghan-Pat Tillman Memorial
Bridge – better known as the Hoover
Dam Bypass Bridge – is one of the most
ambitious construction projects in the
USA. With a span of m between the
twin concrete arches, once complete, it
will be the longest in North America and
the fifth longest concrete arch bridge in
the world. Its apex reaches a height of
4 m over the Colorado River.
Stationary concrete pumps and placing
booms from Putzmeister mastered the
high demands of concrete pumping in
this Colorado River bridge construction
project.
As was done 76 years ago, the Hoover Dam
is again making its mark in history books.
Crews are conquering an engineering feat of
constructing the most technically challenging
bridge ever to be built in North America,
the Colorado River Bridge. To help place
concrete for this one-of-a-kind project, two
Putzmeister placing booms and BSA trailer
pumps are taking on the obstacles presented
by the Hoover Dam surroundings.
The bridge is part of the Hoover Dam Bypass
project, will hover around 274 m above the
Colorado River and run parallel to the dam.
The bridge, with two lanes in each direction,
is being built in an effort to alleviate traffic
on U.S. Highway 93, which currently crosses
the Hoover Dam to pass over the Colorado
River.
Because the highway is the major commercial
corridor between Arizona, Nevada and
Utah as well as on the North American Free
Trade Agreement (NAFTA) route between
Mexico and Canada, the traffic congestion
(an average of 14,000 vehicles a day) caused
by the existing highway across the dam,
imposes a serious economic burden to the
country.
In addition, the traffic volumes, combined
with the sharp curves of the highway near
the Hoover Dam, create a potentially dangerous
situation for Hoover Dam visitors
and dam facilities. Once the Colorado River
Bridge is complete, no through or truck traffic
will be allowed on the existing roadway;
only Hoover Dam visitors will be permitted.
Choosing the right system
Planned amounts of concrete and steel for bridge construction
Obayashi/PSM JV, a joint venture of Obayashi
Corporation and PSM Construction USA,
Inc., the general contractor, began construction
on the 579 m long open spandrel deck
arch bridge in early 2005.
Obayashi/PSM JV had its work cut out for
them; the project included the pre-casting
and erection of pier columns up to 91 m tall;
construction of the twin, cast-in-place segmental
concrete arch spans; and the installation
of temporary twin cable stays that have
a 762 m span and are 101 m tall to support
the arches during construction.
“We called Putzmeister right away to discuss
the project and what our possible concrete
placing solutions for this complicated project
would be,” says Wes Pollnow, construction
manager of Obayashi/PSM JV. “We
needed to know which solution would make
the most sense and which would be most efficient;
they have a true complete systems
69 N/mm 2 concrete in the arches 6,499 m 3
41 N/mm 2 concrete in the pier columns and caps 6,395 m 3
31 N/mm 2 concrete in the bridge deck 4,193 m 3
28 N/mm 2 concrete in the footings and abutments 5,106 m 3
21 N/mm 2 concrete for column infill 1,575 m 3
Reinforcing steel 3,765 t
Structural steel 3,084 t
Post-tensioning steel (permanent) 384 t
Post-tensioning steel (temporary) 680 t
approach, helping us from the beginning of
the project.
The placing system they chose to maximize
their concrete placement for the arch was
MX 32-4 Multi and MX 36-4 Multi placing
booms and BSA 2107 HP-E and BSA 2109
H-E trailer pumps.”
Overcoming the extreme
To date, Obayashi/PSM JV has pumped and
placed about 10,000 cubic yards (7,646 m 3 )
of concrete for the Colorado River Bridge.
Jeff St. John, project manager of Obayashi/
PSM JV, says the pump manufacturer helped
their team determine how and where to
mount the placing booms and position the
trailer pumps for all portions of the project.
“For construction of the twin arches, we positioned
one trailer pump near the base of
the Nevada arches and one on top of the arch
footing in Arizona,” comments St. John. “A
placing boom was also positioned on each
the Nevada and Arizona side of the twin
arches.”
The separate placing booms and their pedestals
were flown via crane to each of the twin
arches for mounting on their specially-designed
platforms.
As a result of the blazing heat, and to
prevent traffic problems, most of the
concreting was carried out at night.
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In order to avoid the intense heat and avoid
traffi c congestion, most of the concrete placements
occurred at night. Once the placing
booms and trailer pumps were in position,
they were ready to step up to overcome the
38 °C weather, while pumping and placing
the notorious, harsh Nevada concrete mix
up 85 m and out 162 m.
“All of the concrete mixes used for the arch
were advanced concrete mix designs using
harsh aggregates,” says St. John. “Liquid
nitrogen has been used extensively for precooling
of the concrete in order to reduce the
temperature the concrete reaches during curing.”
For the arches, a high-strength 69 N/mm 2
concrete mix was used, and for the columns
and pier caps a high-strength 41 N/mm 2 mix
was used.
Early in the project the concrete mixes were
provided by Casino Ready Mix and Silver
State Materials (now a part of the CalPortland
Company), however in late 2007 Obayashi/PSM
JV began operating their own
concrete batch plant for the arch and deck
concrete, and will continue to make their
own until the project is complete.
“Even with the combination of the heat and
the harsh mix, the trailer pumps were able to
easily maintain a continuous concrete fl ow,
at a timely pace, up to the placing booms
so it would not clog the pipe system in the
extreme conditions,” comments Pollnow. “In
addition, the S-valves on the pumps had no
problem gulping down the tough concrete
mixes.”
The trailer pumps are able to provide a
smooth, more controllable output of concrete
because of each pump’s free fl ow hydraulic
technology. Both pumps have a fully adjustable
volume control to allow very slow pumping
while retaining full concrete pressure.
The pumps have been outputting around
12 m 3 /h due to the job site’s extraordinary
environment conditions.
“The pumps really provided that extra
muscle we needed to push the concrete up
and out to its fi nal destination, and in fact,
both trailer pumps have the capability to
pump concrete up to 244 m high. Also, the
capabilities of the placing booms helped immensely
to reach the exact point of concrete
placement for each segment of the twin
arches. Again, because of the unconventional
setup, we really needed dependable
booms, and they did not disappoint.”
t The airy workplace for the
placing booms
21
On site On site
Quinn Concrete Pumping, Las Vegas
Quinn Concrete Pumping, Inc. (Quinn) of Las
Vegas has also lent its services to the Colorado
River Bridge project. Quinn has supplied
both pump operators and has provided their
own Putzmeister equipment.
“Quinn was on site quite early on in the
project for the footing and arch foundation
concrete,” notes St. John. “They are a great
team to work with, very dependable. We expect
they’ll also be involved with placing the
deck concrete as well.”
Most notably, Quinn’s M 42 and M 58 truckmounted
concrete boom pumps were on site
back in 2005 to pump and place concrete for
the Colorado River Bridge’s pier. The pier
provides foundation for the vertical columns
needed to support the arch of the bridge.
Hoover Dam Bypass Bridge
Owner/Developer:
Federal Highway Administration/Washington,
D.C. · Arizona Department of Transportation/Phoenix,
Arizona · Nevada Department
of Transportation/Carson City,
Nevada · U.S. Bureau of Reclamation · National
Park Service · Western Area Power
Administration/Lakewood, Colorado
Design Team:
T.Y. Lin International/San Francisco, California
· HDR Engineering · Sverdrup Civil,
Inc.
General Contractor, Concrete pump
supplier and concrete ready mix
supplier:
Obayashi/PSM JV, a Joint Venture of Obayashi
Corporation and PSM Construction
USA, Inc./Boulder City, Nevada
Concrete pump sub-contractor:
Quinn Concrete Pumping, Inc./Las Vegas,
Nevada
Additional concrete ready mix
suppliers:
Casino Ready Mix/Las Vegas, Nevada · Silver
State Materials/Las Vegas, Nevada
Equipment:
Obayashi/PSM JV: Stationary concrete
pumps BSA 2107 HP-E and BSA 2109 H-
E, placing booms MX 32-4 Multi and MX
36-4 Multi
Quinn Concrete Pumping: M 42 and M 52
truck-mounted concrete pumps
“The 58-meter boom pump was positioned
atop a cliff’s edge on site, and used its full
boom length to place concrete into the hopper
of the M 42 which was situated in a gorge
below on another cliff,” says Pollnow. “The
M 42 then stretched its boom to pump and
place the concrete to its fi nal destination.
The equipment setup and performance was
truly remarkable.”
As of October 2009, Quinn has placed about
3,823 m 3 for the Colorado River Bridge project
and about 80 percent of the bridge was
complete. The remaining work on the project
includes erecting the precast spandrel
columns, installing tub girders, casting the
pier caps, the deck, then the barrier walls
and approach slabs.
Concrete placement is anticipated to be complete
during summer 2010, with the bridge
opening for public use in November 2010. ■
‚ The Hoover Dam –
interesting and intriguing
Concrete on a huge scale
The Hoover Dam was constructed as an
arch gravity dam between 1931 and 1935
with a height of 221 m and a crest width
of about 14 m. The base width is 201 m.
Approximately 2.6 million m 3 of concrete
was used in the construction of the dam.
The dam was not cast as a single piece but,
instead, was created from a large number
of individual trapezoidal concrete blocks
that were 1.5 m in height. Each block contained
a series of pipelines through which
the cool water circulated. As a result, the
heat that is produced as the concrete sets
is conducted away at a considerably quicker
rate. Without this measure, the concrete
would have taken approximately 105 years
to cool!
p Each state had a stationary concrete
pump: one in Nevada and one on the
Arizona-side of the Colorado River.
Boulder Dam? Hoover Dam?
Originally started as the “Boulder Dam”
project, the dam was renamed to “Hoover
Dam” at the beginning of the offi cial
construction phase. At this time, Herbert
C. Hoover was standing for re-election as
president. Despite linking his name to this
construction project, which created many
thousands of jobs during the Great Depression,
Hoover lost the election. In 1933, the
dam was again called Boulder Dam, but 14
years later, and ever since, the dam was
again called Hoover Dam.
The metropolis of gambling grew as
the dam grew
The town of Boulder City was built specifi
cally to house workers involved in the
construction along with their families.
How ever, gambling and alcohol were prohibited
in Boulder City. It was therefore only
logical for workers to use their free time
to make the pilgrimage to the small desert
settlement of Las Vegas, 50 km away. Bars
and Casinos started to emerge in no time.
Las Vegas without electricity? Unimaginable!
However, a curious fact is that at the
time when the electricity purchasing rights
from the hydroelectric power station at the
Hoover Dam were being negotiated, the
desert city‘s mayor at that time rejected
any purchase, saying “Las Vegas will never
have more than 5,000 inhabitants”. As
a result, Las Vegas currently only receives
about three percent of its annual electricity
demand from the nearby Hoover Dam
hydroelectric station.
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On site On site
Russia – vast country,
long journey: 9,000 km
by train to the site
24
In March of this year, a brand new M 6 -6
travelled over 9,000 kilometres on the
Trans-Siberian Railway from Moscow to
Vladivostok.
The customer – Stroitel’nyi Aljans – is currently
using this long-reach boom pump 180
km away in Nakhodka, a port city on the Pacifi
c coast of the Russian Far East. Together
with its older brother – an M 44-5 that was
manufactured in 1996 and that Stroitel’nyi
Aljans acquired second-hand from Japan in
2004 – the M 62-6 is concreting the base of
a large oil platform.
t Well lashed – in Moscow, the M 6 -6
commences its long journey to the far
east with the Trans-Siberian Railway.
q In the port city of Nakhodka, the
M 6 -6 and M 44-5 together are pumping
a total of 55,000 cubic metres of
concrete for an oil platform.
25
This GBS – Gravity Based Structure – consists
of a concrete slab that has an area of
approximately 100 x 127 m and is 13 m
thick and on which four shaft towers – 25 m
in dia meter and 41 m high – will be erected.
The complete structure will be concreted on
land and will then be towed by ship to an oil
fi eld just off the coast of the island of Sakhalin
and, from there, it will be lowered to the
seabed at a depth of 35 m. The client is the
Norwegian company Aker Solutions.
In total, the two Putzmeister pumps will
place 55,000 cubic metres of concrete before
the end of 2011. ■
‚ www.sakhalin.ru/engl/
Information about Russia‘s largest
island (engl.)
‚ www.sakhalin1.com/en/
Information about the oil and gas
development of Sakhalin-1 (engl.)
‚ www.waytorussia.net
Written and researched by the locals,
“Way to Russia” is a very popular independent
guide to Russia online (engl.)
Sakhalin – affectionately named “the wild
dishevelled animal” in the language of the
indigenous people – is 948 km long and between
27 and 160 km wide and is situated to
the north of the Japanese island of Hokkaido
in the Pacifi c.
With 650,000 inhabitants, this is Russia‘s
biggest island and only 3,150 of these inhabitants
belong to the indigenous groups of the
Nivkh, Nani, Orok and Evenki. They live selfsuffi
ciently, as fi shermen, as herdsmen or by
collecting wild plants.
Ceded to the Russian Empire in 1875, the
south of the island was ruled by Japan from
1905 until 1945. The few remaining indige-
Vast oil and gas reserves
in the Russian Far East
An area just off the coast of the island of
Sakhalin in the far north-east of Russia
is said to contain the largest untapped reserves
of oil and gas in the world. In oil
alone, it is estimated that there are 13 billion
barrels in this area.
The Arkutun-Dagi fi eld – part of the
Sakhalin-1 project and the future site of
use for the GBS that is currently under
construction in Nakhodka – is located
only a few kilometres off the coast of Sakhalin.
The US oil company Exxon-Mobil is
investing about 12 billion US dollars in
the development of the three oil and gas
fi elds (in total), amounting to the largest
direct investment by a foreign company
in Russia to date. Approximately 13,000
jobs have been created (directly and indi-
nous people were forced to leave their homeland
and travel in the direction of Hokkaido.
Since the 19th century, the island had been
used as a penal colony for Russian prisoners.
The inhabitants who live there today – except
for those who immigrated as a result of
the raw materials boom – are descendants of
the former forced labourers.
With approximately 175,000 inhabitants,
the island‘s capital Yuzhno-Sakhalinsk is
the largest city on the island. However, most
of Sakhalin is made up of largely untouched
boreal forest or mountains and has a population
density of 6.2 inhabitants per square
metre – half as much as in Norway.
Sakhalin – Сахалин
rectly) from the development of these raw
material reserves and the tax revenue for
the region has doubled. The island has the
highest proportion of foreign nationals of
all the Russian regions and an above-average
share of English-speaking Russians.
Sakhalin is currently trying to fi nd a balance
between becoming an ambitious economic
region and nature resort, between tourism
ambitions and the threat of damage to the
environment.
q (from left to right) Cape Tihii (“Quiet
Cape”) in the Sea of Okhotsk · Nivkh
hunters in their traditional dress · The
state museum in Yuzhno-Sakhalinsk
provides evidence of the former Japanese
reign · The island of Zametny in the
Tihaya Bay
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China
North Korea
Nakhodka
Sea of Okhotsk
Hokkaido
Russia
Sakhalin
Arctic Ocean
Arkutun-Dagi
oil and natural
gas fi eld
Kamchatka
Peninsula
Kuril Islands
Pazifi c Ocean
27 28 29 30
26

50 questions 50 questions
9
The company · Question 9
How does Putzmeister manage
to be such a global presence?
32
Putzmeister promises “Competence
near you”. This is a bold claim for a company
whose customers are dispersed
all around the world. It‘s a claim that
Putzmeister lives up to with modern
communications technologies, a dense
service network and the best possible
relationships with distribution partners
in every corner of the globe.
Since Putzmeister sold its fi rst machine
abroad, the company has gradually opened
up one world market after another. Peter
Dörr was an instrumental part of this process.
Since 1984, the 67-year-old has travelled
the Near East and the countries of Asia
in order to sell machines made in Aichtal.
And his record is a successful one.
Asked about the secret of his success, Dörr
doesn‘t take long to fi nd a response: “You
have to be interested in people. Of course,
you also need a good product. But interpersonal
relationships are crucial. If you want
to be successful in a foreign country, you
need to have distribution partners there who
are prepared to nurture these relationships
and will be there for their customers 100
percent.”
Hoang Minh Hung is one of these distribution
partners. The 47-year-old represents
Putzmeister in Vietnam. “He‘ll bend over
backwards for us and his customers whenever
it‘s necessary,” says Peter Dörr. When
Dörr fi rst met Hung back in 1993, Hung had
no capital. What he did have, however, were
intimate and trusted ties with many potential
customers, and he was convinced by
Putzmeister products. Dörr gave Hung a moped.
They would dash through Hanoi and Ho
Chi Minh City, sometimes even side by side,
to visit customers and deliver spare parts.
?
We‘ve picked 50 questions from
over 50 years of Putzmeister and
given the answers some serious
thought.
From now on, we‘ll be featuring one
question in each new edition.
“In Vietnam, we started out as a tiny operation.
We sold our fi rst machine at an agricultural
trade fair,” recalls Dörr. Hoang Minh
Hung turned out to be a born entrepreneur.
In 2001, he employed a technician for the
after-sales service and set up a small spare
parts warehouse in Hanoi. His company,
Minh Hoang & Co, now has 20 employees
and two offi ces in Hanoi and Ho Chi Minh
City.
Many Putzmeister distribution partners
all over the world can tell a similar story.
“These partners have grown with us. This
results in very close and resilient relationships,”
says Dörr.
A close network of specialists
Putzmeister has mostly been blessed with a
lucky touch when it comes to the selection
of distribution partners. The worldwide service
and distribution network of Putzmeister
subsidiaries and dealers is now present in
more than 100 countries. The headquarters
in Aichtal and the regional subsidiaries offer
support in the form of service engineers,
training specialists and a team of service
technicians.
Together, they ensure that Putzmeister customers
always receive competent advice, are
effi ciently supplied with spare parts and can
depend on a speedy and reliable after-sales
service, no matter where in the world their
machines are put to use.
In many cases, Putzmeister service technicians
do not even need to visit the site.
Thanks to modern telecommunication technologies,
they can often diagnose and rectify
fault causes easily from their PC.
This is how Putzmeister continues to guarantee
“Competence near you” worldwide. ■
q Hoang Minh Hung ( nd from left) with his family and the partners of Putzmeister:
Friedemann Bornträger ( rd from left), Peter Dörr ( nd from right) and Johnson Ong
(far right)
31
p Since the 1990s, Putzmeister concrete pumps have even serviced Vietnamese
construction sites.
q A Putzmeister stationary concrete pump
on the way through the streets of Hanoi.
Our Putzmeister Partner in Vietnam:
Minh Hoang & Co.
4 Pham Huy Thong · Hanoi
Mr. Hoang Minh Hung
Tel: +84-4- 1 950
Fax: +84-4- 1 95
E-mail: mhc-hanoi@hn.vnn.vn
q In Vietnam, the motto is “even the
smallest moped has room”.
33 34
16 PM 4307 GB PM 4307 GB 1

On site On site
MXKD 50 and BSA 110 HP D
concreting the underground
rail station in Yenikapı / Istanbul
ISTANBUL
Historic
city center
MXKD 50 at the centre
of an archaeological sensation
Yenikapı
The construction of a new, state-of-the-art
transport interchange is supposed to be underway
here, in Yenikapı, on the European
side of the Bosporus: a major rail transit
station to serve the 15-million metropolis of
Istanbul. When the ground was broken back
in 2004, nobody thought that the project
would be set back by the discovery of an important
transport hub from Constantinople‘s
past.
First of all, the excavation of the pit for the
new, 21st century subway station on the
Marmaray tunnel line unearthed a series of
ancient walls. As it turned out, these belonged
to an important Byzantine trading port,
a transport hub of the “global world” dating
back to around 400 AD. The “Port of Theodosius”
– named after the last ruler of the
Eastern Roman and Byzantine Empire – contained
the remains of, to date, more than 30
ships, the largest single discovery of ship
relics anywhere in the world. Among them
were four Byzantine dromons, the oldest
warships ever to have been discovered. They
must have been sunk around 1000 AD.
Sea of Marmara
Bosporus
Marmaray
tunnel section
What was a great moment for archaeology
(Yenikapı is the largest urban excava tion
and one of the most signifi cant fi nds in Turkey)
has caused developers to suffer serious
time delays and, of course, to incur enormous
costs.
Yenikapı is situated on the southern shore
of Istanbul‘s old town on the Sea of Marmara.
With the future construction of its major
rail transit station serving the “Marmaray”
undersea tunnel under the Bosporus strait,
Yenikapı is intended to offer passengers a
means of changing from overground to un-
35 36
derground trains. Originally, a new regional
train station had also been planned in
order to connect suburban commuter traffi
c to the East-West network. However, this
aspect of the project had to be changed:
such is the importance of the ancient port,
the local heritage trust decided that it
would have to remain exactly where it is.
q Discovery site of one
of the wooden ships
37
In February 010, the time had fi nally
come: an MXKD 50 on a 15 m lattice
tower and a BSA 110 HP D stationary
concrete pump began concreting the
Yenikapı railway station.
This is the only station of the new Marmaray
tunnel line being constructed using the cutand-cover
method. Its bottom surface mea-
t Pipeline fastenings
in the horizontal section
ZX 1 5/5”-1 0 bar
sures approximately 300 m long and 35 m
wide. For the concreting of the foundations,
it was divided into a total of 29 sections.
Each section – approximately 10 x 35 m
and 2 m thick – is being concreted monolithically
in multiple layers of 40 cm. Each
layer contains some 120 m 3 concrete, which
produces an average of 650 m 3 for each of
the 29 sections.
.
Technical data BSA 110 HP D
Output up to 102 m 3 /h
Concrete pressure up to 220 bar
Engine 330 kW Diesel
Delivery cylinder Ø 200 mm
Stroke 2100 mm
q While some go to work with heavy machinery, others require rather more delicate tools, such as a trowels and brushes.
In the foreground are unearthed fragments of the ancient harbour wall.
18 PM 4307 GB PM 4307 GB 19
38
39

On site
p Hydraulic gate valve GVHM / converted
for installation in a vertical line
Five set-up sites are planned for the MXKD
50, which will all enable it to reach each
point of the foundation area. This means
that it will have to be relocated four times.
The boom anchor set is located in the centre
of the reinforcement of one of the foundation
sections. As the boom foundation needs
to have a certain amount of strength before
subsequent anchoring can take place, a
defi ned workfl ow has been planned for the
40 41
p The hopper of the stationary concrete pump is cleaned under high pressure, and
cleansing water is then pumped through forwards.
concreting of the individual positions. When
each section gets its turn is absolutely crucial
to avoiding unnecessary waiting times
in the re-siting of the lattice tower.
The concrete mix is particularly challenging.
Despite a strength class of “only” C40, the
high additives content makes it awkward to
pump. These additives are necessary because
the concrete must be able to withstand a
high groundwater pressure.
In total, the concreting time of the subway
station (foundations, walls, shafts, etc.) is estimated
to take 15 months to complete. ■
q The huge stationary boom at the
start of foundation concreting.
In the background are the tunnels of
the future underground line.
42
Launch of the fi rst
dredging boat in China
with solids pump
KOS 5100
At exactly 9:09 am on 6th June, 2010, the
ship “Guohai I” (Chinese Sea) was named
and launched at the port of Rongcheng (in
the province of Shandong) in an offi cial
ceremony.
This dredger from the Chinese manufacturer
Guohai Meister (a co-operation partner
of Putzmeister Solid Pumps GmbH)
is the fi rst dredger that has integrated a
KOS 25100 piston pump and transports
the sludge in a closed pipeline.
The dredging sludge can be pumped
across longer distances using a lower water
content and this accelerates the process
of land reclamation considerably.
0 PM 4307 GB PM 4307 GB 1
43
In brief
Putzmeister Academy
Seminars 010/ 011
Our seminar brochures for
2010/2011 (German language),
containing dates and information
about courses and training, will
be sent out by post in October.
In our seminar brochures for
different target groups, we demonstrate
what is important:
preventing accidents, increasincreasing effi ciency and lowering
costs.
Find out about the current dates for the
next “season”, sign up in good time and
reserve your customised company seminar.
If you have not yet received your copy,
then please contact us by e-mail:
akademie@pmw.de
q Many representatives from the
Chinese regional government and
industry representatives took part in
the offi cial naming ceremony of the
“Guohai I”.
(4th from the right) Gerhard Schäffer
from PSP
44

In brief
Putzmeister at construction sites in India
Essar Oil Refi nery in Jamnagar:
Four truck-mounted
concrete pumps in action
Essar is using the fi rst Putzmeister M 42-5
in India to concrete one of the largest refi
neries in the world at Jamnagar in West
India. Together with three of the eight
M 36 pumps from the fl eet, the “new” edition
pumps reliably throughout the day
and night.
The Putzmeister India After Sales & Parts
Service is regarded highly by the people at
Essar, but the message from Deepak Kumar
Singh, Managing Director of Essar HED, is
clear: “For me, the machines by Putzmeister
are simply the best for concreting.”
p Teamwork: Three M 6 and the new
M 4 -5 are placing 1,400 m of concrete
Essar Oil
The Essar Oil Refi nery in Vadinar/Jamnagar
in the state of Gujarat lies on
India‘s west coast, ideally located close
to the oil-rich Gulf states. It is one of the
largest refi neries in the world.
The Indian conglomerate, Essar Group,
is active in the fi elds of steel, oil and gas,
energy, communication, transport/logistics,
construction and raw materials.
45
PM 4307 GB PM 4307 GB
Climbing booms and stationary pumps
at the Ruby Mill Tower in Mumbai
At the Ruby Mill construction site in Mumbai,
two MX 32-4T self-climbing stationary
booms and two pumps of the type BSA
1408 HD are being used. In total, 50,000
cubic metres of concrete has to be placed.
1,100 m 3 of concrete is used for each level,
including the ceilings, columns and inner
walls. Two levels are completed each
month.
The pumps are cleaned using sponge balls
and wash-out pigs by simply pumping them
with water. There is no need for any separate
cleaning station.
46
47
Concreting data
Ruby Mill Tower
Concrete Compressive
type strength
Slab M 40 > 40 N/mm 2
Column M 50 > 50 N/mm 2
Inner wall M 50 > 50 N/mm 2
Slump measure (ø) 140 mm
In brief
Concrete delivery
pressure 200 – 220 bar
Once complete, the Ruby Mill Tower will
be 185 m in height and have 34 levels
(four of which are parking areas). The total
usable area of 78,000 m 2 will mostly
be used as offi ce space.
The building was designed by the New
York architects FxFowle, analysis and
design was carried out by LERA and the
Indian company Vascon Engineers undertook
the construction of the building.
Construction commenced in 2007 and
the building should be complete by the
end of 2010.
48

Safe. Clean. Simple.
The new Pin Pour
Work safely and cleanly!
•
•
•
Stop dangerous goosenecks!
The boom is steadier –
constant fl ow of concrete, even at low output
No risk of injury from concrete splatters
Reduce your operating costs!
•
•
•
•
Quick and easy assembly
Less wear of delivery line pipe and end elbow
Economic
Affordable
Order now: Phone +49 (0) 173 3 09 26 63 · spareparts@putzmeister.de
Hotline for technical questions: +49 (0) 7127 599-297
49
for all end
hoses with
Ø 125 mm
50
51
PM 4307 GB