The Magazine for our Customers and Friends - Putzmeister

The Magazine for our Customers and Friends 68
PM 3833 GB

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Content Latest News
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Latest News
PM Office in Dubai
Austria's first 63-metre-high
long reach boom pump
Putzmeister acquires
delivery line manufacturer Esser
Title Story
Meet the Customer:
French concrete pumping service Dacquin
Bridge Construction
Technology
10 Large PUMI® s like it hot
16 5-axle PUMI® with
increased working load
Focus on PM
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High-rise
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Warsaw Pump Service well
prepared for construction boom
Tunnel Construction
Tunnel pipes securely anchored
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Background
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Effective cooperation
Large investments to cut delivery times
Taking it seriously: technical documentation
Practical Tip
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Qatar intensifies construction
of liquid gas tanks
"Life-prolonging" measures
for pipelines
Application
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Setting an example
PUMI ® s – Reliable Partners for Concrete
Transport Plants
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PM Office
in Dubai
Putzmeister AG has been active in Dubai's
booming golf region for almost a year, with
its own affiliated office in the city. The
metropolis of Dubai, in the United Arab
Emirates (UAE), was selected as a location
for a branch office due to its phenomenal
economic growth and excellent infrastructure.
The main task of the Putzmeister Middle
East Representative Office (PMME) in
Dubai is to provide rapid and effective
support to PM customers and dealers in
middle eastern countries. This includes
providing expert consultancy to Putzmeister
agents in the region, for example, in the
facilitation of high-rise building projects,
even during the project planning phase,
organisation of service training courses for
after-sales technicians, and supporting the
local PM agents in negotiations and order
processing.
The Putzmeister branch office occupies a
central location on Sheikh Zayed Road.
From the office there is a view of the most
spectacular construction projects recently
completed in Dubai, and some, such as the
800 m high Burj Dubai, which are still in
construction. The new PM office is equipped
with the latest telecommunications
equipment, and currently has two workplaces.
The new Dubai branch office has enabled
Putzmeister to improve contact with its
agents and customers on the Arabian peninsula,
and to maintain a presence in the
region with its own personnel and premises.
Putzmeister acquires delivery line manufacturer Esser
With effect from October 1st 2006,
Putzmeister has acquired 100 % of the shares
in German company Esser Werke GmbH &
Co.KG (Warstein). With approximately 100
employees, Esser Werke specialises in the
production of highly wear-resistant pipes
from reinforced steel for concrete delivery,
mining, and other industrial sectors.
With the acquisition of a specialist manufacturer
of highly wear-resistant delivery
pipes, Putzmeister has strengthened its
commitment in the area of pipe delivery for
particularly difficult media. Not only do
Austria's first 63-metre-high
long reach
boom pump
In October, Putzmeister agent Eibinger
(headquartered in Soeding, Styria) supplied
Austria's first M 63 long reach boom truckmounted
concrete pump to concrete pump
operator Asamer & Hufnagl (Ohlsdorf,
Upper Austria).
With a vertical reach of around 63 m and
five flexible boom segments, the machine
is the flagship of the Asamer & Hufnagl
fleet and by far the largest truck-mounted
concrete pump in Austria. Previously, the
state-of-the-art Putzmeister 60 m long
Esser Twin Pipes offer a considerably longer
service life than conventional pipes in
truck-mounted concrete pumps, but they
have also been successfully implemented in
stationary concrete pumps and with pressures
of up to 200 bar. Esser Twin Pipes are
widely used in mining and gravel extraction,
for example, for pneumatic stowing.
In the future, Esser delivery pipelines will
continue to be market independently with
the support of two of their own subsidiary
companies and several dealers. Esser products
will be supplied directly to end
reach boom pumps were primarily supplied
to concrete pump services in the USA,
Spain, Germany, and the Middle East. The
pumps supplied are normally the related M
61-4, M 62-6 and M 63-5 models.
Asamer & Hufnagl belongs to the international
group Asamer Holding AG. The holding
company is represented by numerous
companies, particularly in the areas of gravel
and sand extraction, cement manufacturing,
and the production of concrete. The company
fleet includes around 300 truck mixers
and 75 truck-mounted concrete pumps. In
addition to its headquarters in Austria,
Asamer Holding AG is also active in the
Czech Republic, Slovakia, Croatia,
Bulgaria, Romania, and Saudi Arabia.
customers as well as to OEM like
Putzmeister AG and other concrete pump
manufacturers some of whom also have
their own pipe-welding facilities for the
production of concrete delivery lines.
In the new PM subsidiary the former coowner
of the company, Mr. Alexander
Esser will be part of the management. At
the same time, Mr. Uwe Tichy before responsible
for After Sales and Parts Services
of Putzmeister AG, will join the management
of Esser company.
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Title Story
Meet the Customer:
French concrete pumping
service Dacquin
Some pump operators prefer to rely on the
proven, traditional methods of their
machines rather than new technology or a
completely new pump system. Often,
machines are rarely replaced until the old
concrete pump reaches its limits and additional
machines are required. In some
cases, strong partnerships can even develop
between the concrete pump operator
and the concrete pump manufacturer. See
for yourself...
The outskirts of Hesdin, a small town in
Northeast France, is home to the headquarters
of concrete pump operator G. Dacquin
Transport et Location. In the office, we
meet the owner, Monsieur Ghislain
Dacquin, who personally handles telephone
orders for his concrete pumps and schedules
the machines. In the same room, an
employee is busy creating invoices and
checking incoming payments. The atmosphere
is industrious, and neither can spare
much time for conversation.
Impressive working range:
Dacquin machine operator William stretches the boom of his M 42-5 elegantly past the roof of the house to concrete the
patio behind. The whole drive of the house was used to set up the machine.
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Title Story Title Story
The humble reception afforded to visitors
to the pumping service is in stark contrast
to the impressive area that G. Dacquin
covers with his machines. "We find our
construction sites in the five surrounding
Departments of Pas-de-Calais, Nord,
Somme, Seine-Maritime and Oise. This
obviously involves a lot of transportation,
so we operate from three depots, in Lille,
Rouen and Arras", explains Dacquin, the
owner and managing director of the company.
The fleet of concrete pumps consists of one
M 28-4, three M 36-4s and a new M 42-5.
Added to this are four PUMI ® truck mixer
concrete pumps with 21 and 24 metre
booms, two of which are equipped with a
rotor and the other two with CS piston
pumps. Twelve truck mixers that are used
on behalf of the neighbouring concrete
plant complete the Dacquin fleet. The company
currently has 27 employees.
Seasoned veteran – and no shortage of
spare parts
But wait – we nearly forgot to mention a
highlight of the truck-mounted concrete
pump collection. Next to the entrance to
the company premises stands a well maintained
2-axle pump, also bedecked in the
livery of Dacquin pumping services. This is
Proprietor Ghislain Dacquin in his office
an 18-year-old Wibau truck-mounted concrete
pump with triple folding 24-metre
boom and rotor delivery system on a
MB 1619 chassis. Ghislain Dacquin ordered
the machine from Hesse-based company
Wibau in 1988, shortly before its collapse
and subsequent takeover by Putzmeister.
The relatively lightweight truck-mounted
concrete pump with 24-metre drilling
boom (curb weight approx. 16 t) has
provided a reliable service over the years
and is still licensed today. Nowadays,
however, this seasoned veteran only comes
into contact with concrete at busy times
when all other Dacquin concrete pumps are
in use on construction sites. This old-timer,
with its top Z fold system and robust rotor
pump (with an output of 80 m 3 /h), clearly
occupies a special place in the owner's
heart.
18 years old and still running – the old rotor truckmounted
concrete pump with 24-metre boom
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G. Dacquin adopts a dual strategy for his truck mixer concrete pumps – the fleet includes PUMI ® s both with a rotor
system (pictured) and with CS piston pump
Rotor tube replaced in just two hours
In the old Wibau truck-mounted concrete
pump and the two rotor PUMI ® s, Ghislain
Dacquin changes the rotor tube (the only
wearing part of this pump system), after a
throughput of 3,500 m 3 concrete. This replacement
of wearing parts takes just two
hours. While each of the PUMI ® s registers
an annual pump output of approx. 7,000 m 3 ,
the average output of the truck-mounted
pumps is around 20,000 m 3 per year.
For years, G. Dacquin Transport et Location,
founded in 1975, was so convinced by its
rotor truck-mounted concrete pumps that
they showed no interest at all in pistonbased
truck-mounted concrete pumps. The
first contacts with Putzmeister were not
established until a visit by José Blasco,
area sales manager for Putzmeister France,
in the year 2000. Since then, the relationship
has flourished and proven mutually
beneficial.
Although the day-to-day maintenance work
on the concrete pumps is performed in
Dacquin's own workshop, there are also
situations in which the company requests
advice or practical support from the PM
after-sales department. This appears to
work perfectly with Putzmeister France:
"The service guys really know what they
are talking about and can help us quickly
whenever necessary. Often, a simple telephone
call is sufficient to solve the problem."
Rotor system popularity in the early days
Manfred Wacker, a former Wibau
employee and current Putzmeister area
sales manager for concrete pumps,
remembers this machine model well:
"The 80 M 24 BRF truck-mounted concrete
pump with C transfer tube (*) was
a big seller in the 1980s, with large sales
volumes somewhere in the region of 250
units during the seven years it was in
production. The boom, base structure,
and pump were ahead of their time, so
that some examples are still in use today.
The supply of spare parts is not a problem:
components are either stocked at
PM's central warehouse or are still available
for order."
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The PUMI ® transports the 5 m 3 concrete for the patio
base structure to the construction site in its own drum
For information: truck-mounted concrete
pumps with rotor pump system in the
20-metre class are still available from
Putzmeister today. Both models of truckmounted
concrete pump with rotor, the
BQF 24.08 and BQF 28.08, have an output
of 80 m 3 /h, the same as the legendary
Wibau range.
(*) Please note: the designation "BRF"
was used by the manufacturer Wibau as
an abbreviation of the German for
"Truck-mounted concrete pump with
rotor". At Putzmeister, however, the
abbreviation stands for "Truck-mounted
concrete pump with C transfer tube".
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Bridge Construction
Effective cooperation
In edition 63 of the PM Post, we reported
on the concreting of the underwater bored
piles for the new Strelasund bridge. Since
then, work on Germany's most spectacular
bridge construction project – accounting
for 2,831 m of the 4,100 m road link –
has progressed rapidly. The following
article provides an insight into the
concreting of the northern bridge superstructure.
The 2nd Strelasund (Strela Sound) crossing
forms part of the feeder road between
Stralsund and the Island of Ruegen along
the national route B 69n. On completion,
the bridge will significantly alleviate congestion
for holiday traffic and ferry services
running between mainland Germany and
Ruegen Island. The new construction consists
of six separate bridge sections, each
measuring between 317 and 583 m.
Construction is being undertaken by the
company Max Bögl GmbH, & Co.KG.
Client of the project is the Federal Republic
of Germany which is represented by
DEGES ("Deutsche Einheit Fernstraßenplanungs
und -bau GmbH").
Constant "up and down" takes time
The 1,604 m long northern section of the
bridge is a prestressed hollow box construction.
To create the superstructure, a
launching gantry is used along the top. The
hollow box is being concreted in two sections.
On our visit, the concrete integration
was performed firstly with a long reach
boom truck-mounted concrete pump type
BSF 52.20 H, which could be driven across
the already completed southern part of the
Strelasund bridge up to the launching gantry,
where it was set up. This truck pump has
been rented by the concrete supply association
from pumping service Neuland
Beton H.Burgis KG (GmbH & Co.).
Concreting of the northern section was
performed by a stationary Putzmeister
MX 24 concrete placing boom installed on
the launching gantry, supplied with concrete
by a truck-mounted concrete pump
BSF 36.16 H, which was located approx.
16 m beneath the bridge carriageway. To
create a connection to the stationary boom
90 m away, the boom tip of the truckmounted
concrete pump was extended with
an additional delivery line. The most timeconsuming
part of the operation proved not
to be the pumping of the 280 m 3 concrete
required for this section, but instead the
continual hoisting and re-threading of the
end hoses into the reinforcement. Now,
both truck-mounted concrete pumps operate
from the bridge superstructure.
Keeping stress to a minimum
All the concrete, including pumping
services, is undertaken by a supply
association of Cemex Deutschland AG
(Groß Lüdershagen works, near Stralsund)
together with Holcim Beton und
Zuschlagstoffe GmbH (with works in
Stralsund). The required volume is
approx. 75,000 m 3 self-compressing
concrete, ballast concrete, underwater
concrete and normal concrete. In total, the
2nd Strelasund crossing requires 20 different
concrete mixes. The cooperation between
the mixing operation and site management
is exemplary, as Kristina Mahnke,
head of works and sales manager for
Stralsund/Rügen at Cemex AG, explains:
"Max-Bögl site management keeps us
informed of the required quantities of concrete
and the concreting schedule. The
collaboration works extremely well, there
is no unnecessary stress. We know that we
are dealing with professionals, just like
ourselves!"
Kristina Mahnke, head of works and sales for
Stralsund/Rügen at Cemex AG
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MX 24 stationary boom on the launching gantry
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Technology Technology
Large PUMI ® s like it hot
During the course of an impressive celebration
in September with 400 invited
guests, the Al-Tawi Group presented its
first two PUMI ® s in Jeddah (Saudi
Arabia). With its investment in truck
mixer concrete pumps, the company is
showing its interest in also being able to
offer and run economically a pump
service for small volumes of concrete,
the typical PUMI ® sector.
The Al-Tawi PUMI ® 28.89 S on one of its first construction sites in Jeddah
The two identical Putzmeister truck mixer
concrete pumps are model PUMI
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® 28.89 S,
which is increasingly winning respect in
the important export markets. Not only is
the 4-fold boom at 28 m vertical reach
clearly better sized than the truck mixer
concrete pumps otherwise employed from
ready-mixed concrete works with their 21,
24 or 26 metre booms. But the large piston
pump with its 80 m3 /h output is unusually
powerful for a pump mixer. To this must be
added the large diameter (125 mm) of the
delivery line and the 9 m3 capacity mixer
drum. All this makes it clear that the large
PUMI ® s can be similarly heavily used and
economically operated as many truckmounted
concrete pumps with a comparable
working range.
The Al-Tawi Co. goes back to the year
1971, when the firm's founder, Achmed
Al-Tawi, began the industrial production of
tiles and bricks in Bisha, a town in the west
of the Kingdom of Saudi Arabia. Ten years
later, when the demand for ready-mixed
concrete had perceptibly increased, Al-Tawi
started running his first concrete mixing
plant and truck-mounted concrete pump –
a Putzmeister M 32. Today, the Al-Tawi
Company for Ready Mix Concrete &
Cement Products, with over 700 employees,
around 100 truck mixers, 10 concrete mixing
plants (a daily capacity of around 5000 m 3 )
and some 30 truck-mounted concrete
pumps, is one of the giants of the readymixed
concrete sector in Saudi Arabia. The
pump fleet is currently still led by an M 58.
This M 58 is currently Al-Tawi's largest truck-mounted
concrete pump. From the start of 2007, the company
fleet will be headed by a new M 63
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New pumps for the new branch
It has since become clear that the Al-Tawi
Group is not only growing at its Jeddah
site. The company is also about to start
producing concrete in the capital, Riyadh,
with its own, ultramodern mixing plant.
There is a concrete pumping service associated
with the ready-mixed concrete
works. Al-Tawi has assigned a number of
the 17 machines which it ordered from
Putzmeister AG at the start of 2006 to this
service. The order includes two further
large PUMI ® s with 28 metre booms and
two M 63-5 long reach boom pumps. The
first of the two monsters will come into
service at the turn of the year 2006/2007.
The aggregate for concrete production is
taken from the company's own quarries. As
Al-Tawi's modern Liebherr mixing plant
can also mix in ice to cool individual concrete
batches, as required, neither the truck
mixers nor the new truck mixer concrete
pumps require supplementary insulation of
the mixer drum.
Nothing happens without him –
Nasir U.Shariff, Head of Engineering Department
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Headquarters of the Al-Tawi Group in Jeddah
Saeed Al-Tawi, General Director of the Al-Tawi Company
Machines adapted for
high temperatures
Truck manufacturers supply their
vehicles in a special “heat-resistant”
version for operation under the extreme
conditions found on the Arabian peninsula.
These special export versions may
have (depending on the manufacturer
and model) enhanced water and oil cooling
systems, high power fans, strengthened
antiroll bars, additional transmission
oil cooling, air conditioning, etc.
Putzmeister as the bodywork builder
also adapts the hydraulic system of its
concrete pumps and placing booms to
the high ambient temperatures, for
instance by fitting significantly larger
hydraulic fluid radiators. The PUMI ®
truck mixer concrete pumps delivered
to Saudi Arabia with their 9 m 3 drum
have also had their axles and suspensions
strengthened, higher load-bearing
tyres fitted and a larger water tank
installed.
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Focus on PM
Large investments
to cut delivery times
Putzmeister AG is currently increasing its
production capacities in Germany, undertaking
extensive construction work and
investing up to 45 million Euro within two
years. This expansion of production
capacity is urgently required in response
to the continually increasing demand for
high-quality concrete pumps and placing
booms. Construction activities are scheduled
to take place at the main plant in
Aichtal, as well as the highly specialised
PM manufacturing plants in Gründau
and Althengstett. Numerous new construction
projects and expansions are also
planned or already under construction at
Putzmeister sites outside Germany.
Reports on these projects will be published
in later editions of the PM Post.
The prerequisite for the expansion of the
main assembly site in Aichtal was the
enlargement of the factory premises by
approx. 10 %. The focal point of the construction
activities is a new state-of-the-art
paintwork centre covering a roofed surface
area of approx. 7,500 m 2 . The new paintwork
centre will enable several long reach
boom pumps (of 60 metres and above) to
be coated and dried at the same time. The
centre is scheduled to begin operation in
mid 2007. Wolfgang Laux, responsible for
preparation and painting, explains the
benefits: "The new centre will provide five
areas to prepare booms for painting. All
arm assemblies will now be painted completely
with the boom extended and while
mounted on the truck-mounted concrete
pumps. This means that in future, we can
promise faster process flows and even better
paint quality."
In addition, we will also have considerably
more space for customer-specific versions
of the machines (e.g. special coatings and
lettering), and for the finishing process,
which can be particularly complicated.
Finally enough space: Wolfgang Laux looks forward to
"his" new paintwork centre. To the right of this stands
the spacious new logistics area.
Another construction project will create a
new logistics centre for large components
such as base structures and arm assemblies,
which will be located immediately next to
public transport routes. The new logistics
area will include a 1,200 m 2 covered loading
and unloading zone. Putzmeister anticipates
that these measures will significantly
accelerate the material flow within the
plant from January 2007.
The construction of a modern 5-storey office
complex will accomodate Putzmeister's
workforce, which has been steadily increasing
for several years. The building, scheduled
to open in December 2006, covers an
area of around 2,500 m 2 and will house a
modern central data centre, additional training
rooms and office space for approx. 140
employees.
A covered materials reception area, the
expansion of the storage and test area for
truck-mounted concrete pumps, as well as
the provision of new parking spaces for
employees have already been completed in
Summer 2006.
Further projects currently in the planning
phase will expand warehouse capacity by
50 %, resulting in a considerably improved
stock of components. The surface areas of
the associated packaging and shipping area
will double in size, and the loading ramps
are to be fully modernised.
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The materials reception area was already extended
and covered in Summer 2006
The state-of-the-art robot welding systems
at sites in Gründau (near Frankfurt) and
Althengstett (near Calw) have now been
operating 24 hours a day, seven days a
week for over a year. The expansion of
these two Putzmeister locations for steel
processing, with a combined investment of
20 million Euro, ensures that Putzmeister
will continue delivering specialist highquality
components such as placing booms,
base structures, and support systems in the
required quantities in the future, and delivery
times will be further reduced.
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The new 5-storey office building with 2,500 m
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2 of floor space is due to be occupied at the start of 2007 following a
record construction period of just five months
The expansion of the PM works in Althengstett has also
been completed under high pressure – the new building
can be seen to the left of the picture
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High-rise
Warsaw Pump Service well
prepared for construction boom
In Warsaw there has been a real
building frenzy over the last two to
three years. On many construction
sites in the Polish capital, qualified
personnel are now in high demand.
New buildings in particular have been
shooting up at an alarming rate in the
metropolis with nearly two million
inhabitants. The renovation of old
buildings, on the other hand, has still
not reached the same levels as in many
large cities in western Europe.
The current modernisation and expansion project at Warsaw airport requires over 330,000 m 3 of concrete for terminals,
car parks, administrative buildings, and runways. The project is supported by the company Eurotrans with its truckmounted
concrete pumps – pictured is an M 42-5.
At a conference with building trade journalists
in Warsaw at the end of September
2006, Thomasz Jasielski, member of the
board of management of Cemex Polska,
gave some information on the situation of
the Polish building industry. According to
him, there is currently a real shortage of
skilled workers on Polish construction sites
in some professions (tradesmen, truck drivers,
etc.). The reason is due to the migration
of many young specialists to foreign
countries due to the better pay there. In
particular in Warsaw and the big cities on
the Baltic Sea coast, the shortage of skilled
workers has now become a problem.
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Regulation in Poland: machine operator
licence for concrete pump drivers
This assessment of the situation is also
confirmed by Piotr Kisiel, co-owner of the
relatively young Warsaw ready-mixed concrete
manufacturer and pump service
Eurotrans. For him too, it was none too
easy to find qualified machine operators for
his new long reach boom pumps – two
M 42-4 and M 46-5 each and one M 52-5.
In the meantime, the staff problem has been
solved to his full satisfaction. He has entrusted
the operation of his truck-mounted concrete
pumps to extremely careful and exper-
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New residential areas with numerous multi-storey buildings
are rapidly appearing in the area surrounding
Warsaw. An M 52-5 operated by Eurotrans concretes
the base plate for a multi-family house in the Northeast
of the Polish capital.
ienced pump drivers; they all hold the
Polish machine operator licence for concrete
pumps. Pjotr Kichel is very satisfied
with the efficiency of the machines: "We
produce an average of about 5,000 m 3 per
month with each of our concrete pumps!"
In addition to its five Putzmeister pumps
and 55 truck mixers, Eurotrans also operates
a further 100 tipper trucks for gravel and
crushed stone, silo transporters, etc.
In addition to the company headquarters in
Warsaw, Eurotrans also has branches in
Poznan, Gdansk and Plock. Although Piotr
Kisiel is very busy in the office, he also
spends a large part of his working time on
construction sites – and he even enjoys it!
He looks for meetings with the responsible
foreman in the same way that he also personally
deals with space ratios for setting
up his truck-mounted concrete pumps.
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Piotr Kisiel,
Vice President and Managing Director of Eurotrans
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High-quality equipment
of Eurotrans pumps
High-rise
The Eurotrans concrete pumps all have
high-quality equipment. For example, they
are fitted with the joystick-controlled EBCradio
remote control as well as the onesided
OSS narrow gauge support. The
boom delivery line consists essentially of
wear resistant 2-layer pipes, and a 100 bar
high pressure cleaner is also carried on
board with all truck-mounted concrete
pumps. For 2007, Eurotrans has ordered
more machines from the Polish Putzmeister
agent Alltech, based in Sopot and Warsaw.
They will be a useful extension to the
current fleet of long reach boom pumps.
Keeping in touch with the construction sites: Piotr Kisiel (on the right) in discussion with Dipl.-Ing. Pawel Komorowski,
construction manager at Edbud Sp.z.o.o. The construction company frequently uses Eurotrans' M 42-5 and M 46-5
(pictured) for concreting at the new PasaÏ Gadyba shopping centre. The upper storeys of the 38 m high building
accommodate apartments and offices.
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Technology
5-axle PUMI ® with increased working load
In addition to efficient series manufacturing,
Putzmeister production also excels at
offering specialised customer-specific
solutions. One recent customer to benefit
from this offering was Andrey-Transporte
AG from Switzerland, who commissioned
Putzmeister to produce an unusual
PUMI ® truck mixer concrete pump. The
PUMI ® 28.69 S was built on a Mercedes
Benz chassis. You may think this is
nothing unusual, but the chassis in question
was a 5-axle chassis of the model
Actros 4144 10x4.
In Switzerland, a gross weight of 40 tonnes
is permitted for this type of chassis. This
represents an additional working load of
approx. 6 tonnes in comparison to a 4-axle
chassis (once the weight of the additional
axle is taken into account), for which only
32 t is permitted. The Andrey company,
based in St.Silvester (in the Swiss canton
of Fribourg) wanted to utilise the full
capacity of this legal specification.
For the truck superstructure, Putzmeister
used a standard chassis (5,100 mm wheelbase)
manufactured by Paul in Passau,
equipped with an additional steered pusher
axle. We then had to find a new position in
which to attach all the fittings, such as the
diesel tank, compressor, battery housing,
etc. In view of the considerable space
restrictions caused by the additional axle,
this was no simple task.
Reduced delivery line diameter allows
smaller extent of supports
The PUMI ® designed for Andrey has a
4-part 28-metre boom and a delivery line
with a nominal diameter of 100. Since a
28-metre boom is normally associated with
a 125 diameter delivery line, it was possible
to reduce the extent of supports at the front
to 4.5 m, due to the smaller delivery line
cross section with a lower load moment.
Despite an extensive horizontal reach, the
PUMI ® can still be erected even if space is
at a premium.
For the core pump, Andrey chose the powerful
TMP 1006 S piston pump integrated
longitudinally in the direction of travel.
With a 1,000 mm stroke and 230 mm diameter
delivery cylinder, this is among the
most powerful pump systems in the PUMI ®
core pump range. This PUMI ® features a
concrete pressure of up to 75 bar and
67 m 3 /h output with 27 switchovers of the
S transfer tube per minute, thus offering
powerful yet smooth pump performance.
Thanks to the low switch frequency and
EPS control system (see info box), the
boom remains still, even at higher outputs.
The 9 m 3 mixer drum offers an impressive
concrete capacity, more than sufficient for
the numerous small construction sites on
which PUMI ® s are typically used. On construction
sites with a greater demand for
concrete, the large Putzmeister truck mixer
concrete pump can bridge the wait time
between two mixers using concrete output
from its own drum.
In creating the custom Swiss PUMI ® ,
Putzmeister had to design some specialised
solutions. Despite these challenges, we
succeeded in developing a highly attractive
truck mixer concrete pump specifically
suitable for the Swiss market, while also
taking into account individual customer
requirements.
37
The PUMI ® 's 28-metre boom requires just 4.5 m extent
of supports
EPS control system
All Putzmeister's PUMI ® truck mixer
concrete pumps are equipped with EPS
(Ergonic ® Pump System) control
systems – and, as of BAUMA 2007,
EPS will be included as a standard feature
in all truck-mounted concrete
pumps. The electronic control system
prevents pressure peaks in the hydraulic
system, which otherwise develop when
the transfer tubes are switched over.
This helps to achieve an almost constant
flow of concrete by triggering the
switch impulse before the delivery
piston end position is reached.
Furthermore, the EPS control system
can also be used to restrict hydraulic
pressure – and hence also the expected
concrete pressure. This is an important
aspect, for example, if delivering concrete
through hoses or pipes for which it
is not possible to accurately estimate the
pressure (e.g. due to unknown wall
thickness), for pumping lightweight
concrete (lower pressure prevents blockages),
etc.
Advantages of EPS at a glance:
■ Smoother pumping process
■ Quieter operation
due to "Silence" function
■ Less wear
■ Lower fuel consumption
■ Fewer hydraulic components
38
Qatar intensifies
construction of
liquid gas tanks
Increasing energy prices are making the
construction of gas liquefaction plants
and high-volume liquid gas holders
increasingly attractive. In this regard, in
issues 54 and 65 of Putzmeister Post we
reported about projects in Norway and
Spain, in whose completion Putzmeister
concrete pumps were playing a decisive
role.
It was mentioned in these articles that the
volume of Liquefied Natural Gas (LNG) at
a temperature of minus 163 °C is only
around 1/600 of its volume in a gaseous
state. At distances in excess of 3,000 km,
transportation using special tanker ships
makes particular financial sense.
A Putzmeister M 52-5 pumps cryogenic concrete into the climbing formwork
High-rise
Since then, natural gas liquefaction projects
and the construction of LNG holders have
surged forward in Qatar. The Emirate in the
Persian Gulf has at its disposal, in the area
around Ras Laffan, one of world's largest
natural gas deposits and is planning to triple
its output of LNG to 77 million tonnes by
2010.
The Lebanese construction firm Kettaneh is
currently building three large LNG tanks in
Ras Laffan. Their dimensions are impressive:
80 m in diameter, an overall height of
around 50 m and with a ring wall thickness
of approximately 0.8 m. The tanks are of a
triple-shell construction with concrete walls,
insulation and steel plating (from the outside
inwards). Concreting is accomplished using
a climbing formwork, which is filled with
cryogenic concrete by two Putzmeister
M 52-5 long reach boom truck-mounted
concrete pumps, and one M 42-5. Ring by
ring, the 3.5 m high formwork sections are
filled with concrete. In this way after some
12 weeks, the tank's exterior walls are
finished, up to a height of 40 m. The three
truck-mounted concrete pumps are part of
the fleet of Qatar Readymix, which is also
delivering the concrete to the LNG tank
construction sites.
39
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18
PM 3833 GB
Tunnel Construction
Tunnel pipes
securely anchored
An impressive tunnel building project in
Spain's capital, Madrid, is beginning to
take shape. The project is to run the
southern section of the heavily used M30
urban motorway under the earth's surface.
A number of Putzmeister pumps have
been used here for placing concrete and
for backfilling the tubbing with special
mortar. Pumping distances of 600 m, high
air humidity and harsh continuous
operation were on the agenda at this
mammoth construction site.
The tunnels are being built by a consortium
consisting of the Spanish construction firms
FCC and Dragados. The planned construction
time is 30 months. At the start of work,
build costs were estimated at 740 million
Euro.
Driving of the two tunnels by machine
(3,650 m in the northern bore, 3,550 m in
the southern) has now been completed.
The consortium has used two of the largest
tunnelling machines in the world, built by
Herrenknecht and Mitsubishi. Advancing
with an EPB shield, the tunnelling machines,
weighing over 4,000 tons with up to 160 m
of trailing machinery, have bored through
Madrid's clay and gypsum subsoil in a
boring cross-section of over 180 m 2 . Twometre
wide tubbing rings each comprising
nine elements and a keystone were set as
progress was made.
10 fine concrete pumps integrated into
the tunnelling machine
While the southern bore was being advanced,
six KOV DUO 550 PM pumps with
ball valves were used to fill the annular gap
between the tunnelling face (15.20 m diameter)
and the external radius of the concrete
rings (14.65 m diameter). Four further
ball valve pumps (KOV 1050) were used to
transport the mortar material from silos. All
ten Putzmeister pumps were integrated on
the backup for this purpose. Thus, as the
site was working a three-shift system, the
PM ball valve pumps were in use 24 hours
a day, seven days a week in 95 % air humidity.
The delivery systems ran in a fully
automated mode as the tunnel was driven
from the centre control room of the EPB.
The tunnelling machines for the M30 motorway tunnel have a diameter of over
15 m. Pictured is the tunnelling machine supplied by Mitsubishi Heavy Industries
The KOV DUO double piston pumps each
loaded one injection line with each of its
delivery pistons to backfill the M30 tunnel
pipes. The special silicate-sand mortar
(maximum particle size 4 mm) backfilling
material was supplied to the KOV DUOs
by four similarly constructed KOV 1050s,
which drew the backfilling mortar down
continuously from two mortar storage
tanks. However, on these KOVs the two
pistons alternately fed a pump line. The
material was delivered 50 m horizontally
and 15 m vertically. The delivery pressures
of both the KOV 1050 transport pumps and
the KOV DUO 550 injection pumps were
limited by Putzmeister service engineers
because of the low delivery distances to
40 bar and 48 bar respectively. Pressure
sensors were also used to ensure that a
maximum injection pressure was not
exceeded as the annular gap was backfilled.
KOV
Ball-valve-controlled 2-cylinder piston
pump for pumping in a shared line
KOV DUO
Ball-valve-controlled 2-cylinder piston
pump for simultaneous feeding
of two separate lines
(Photo: MHI / Duro Felguera)
EPB shield (EPB – Earth
Pressure Balance)
Tunnelling machines with EPB shields
are predominantly used to bore through
densely stratified earth with a soft or
pulpy consistency. Only the soil cut by
the tunnelling machine's cutting wheel
is used as the supporting medium.
Further supporting media such as compressed
air or bentonite suspensions are
not used. Other tunnelling machine
technologies may be used depending on
the prevailing geology, e.g. slurry
shield, partial removal shield, mixed
shield, etc.
41
40
Concrete pumps for long distances
The consortium leased a Putzmeister truckmounted
concrete pump with a 42-metre
boom from a local pumping service,
Ibérica de Bombeos Especiales, for the
numerous concreting jobs in the tunnel.
The machine was set up on the surface
immediately adjacent to one of the shafts
so that it was possible to deliver concrete
vertically downwards through the placing
boom. The concrete was then supplied
through the end hose on the boom tip to a
BSA 2109 stationary concrete pump located
in the tunnel and also provided by
Ibérica de Bombeos Especiales. This ran as
a kind of relay station and delivered the
concrete up to 600 m through a connected
SK pump line. The truck-mounted concrete
pump and stationary concrete pump set-up
with its pipeline was used a number of
times during the construction work.
The two tunnel bores, with an internal diameter
of 13.45 m, are sized so that on completion
they can accept a carriageway bed
with three lanes and two strips at the side.
The carriageway bed consists of 60 cm
thick pre-stressed concrete prefabricated
components which then lie on brackets
concreted into the inside of the tubbing.
The entire ventilation system is accommodated
in the roof of the tunnel while there is
a service and rescue route beneath the
carriageway bed. Cross tunnels connect the
two bores every 200 m.
7 KOV-Duo pumps delivered the injection mortar
behind the concrete preform
KOV pumps for free-flowing
media with a high solids content
Putzmeister has developed the KOV
series of ball-valve-controlled pumps for
the delivery of fine concrete, mortars and
low consistency slurries with a maximum
particle size of 8 mm. These pumps are
supplied in two basic versions (KOV
and KOV DUO) and in varying performance
classes. This makes it possible to
achieve delivery rates of 6 to 60 m 3 /h
and pump pressures of up to 130 bar.
Tunnel Construction
The long-range concrete pumping was performed by a BSA 2109, supplied by a truck-mounted concrete pump
43
situated outside the tunnel
44 45
Four KOV 1050s were used to transport the mortar
from these reservoirs to the actual injection pumps
The concrete was pumped over a horizontal range of
up to 600 m
Mortar injection pumps ergonomically positioned on the trailing axle of the tunnelling machine
42
46
19
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20
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Background
Taking it seriously: technical documentation
Rudi Scherrle, Technical Documentation Manager, inspects a spare parts sheet on the screen with colleague Lisa Braun
For industrial equipment such as concrete
pumps, a minimum level of technical
documentation is required by law. Since
1995, compliance with this "Machine
Directive" is regulated by an EU ordinance,
which primarily affects the safety and
operating instructions of the products.
Putzmeister offers even more.
Putzmeister AG is not satisfied with merely
providing legally "watertight" user information
for its machines. Beyond these basic
legal requirements, easily comprehensible
documentation, supported by memorable
drawings and clear pictograms, prevents
the user from making operating errors,
reduces the service workload, and minimises
downtime.
For this reason, the Technical Documentation
department at Putzmeister goes to great
lengths to ensure our documentation is as
user-friendly as possible. The DOC-cert
certification, awarded by the independent
technical assessment body TÜV, and
assessed in annual inspections, confirms
the exemplary quality and high standard of
our operating instructions in terms userfriendliness,
safety, and
completeness.
Large range of variants requires
machine-specific documentation
In the Technical Documentation department,
a specialist team of 16 technical
authors, technical illustrators, and technical
translators prepare the detailed, technical,
and safety information materials for concrete
pumps and placing booms. The documents
are not developed for a particular
model of concrete pump or placing boom,
but are created individually for each
machine supplied. Putzmeister therefore
caters specifically for the wide range of
variants of its products. Rudi Scherrle,
head of technical documentation at PM,
describes the situation: "Nearly all our
machines are customer-specific, and are
therefore unique".
47
The clearly structured documentation is
supplied in a DocuBox and is currently
available in 23 languages. The DocuBox is
included with every machine supplied and
is divided between four folders which are
marked in different colours depending on
whether they are intended for machine operators,
workshop employees, or Putzmeister
service personnel:
■ Technical data (machine card and circuit
diagrams)
■ Operation instructions and declaration
of conformity
■ Spare parts list (also on CD), and
■ Technical appendix (including a check
book, safety manual, safety regulations
for machine operators on CD
("Computer Based Training" – CBT 1).
When new machine models are developed,
such as those exhibited at BAUMA 2007,
for example, the technical departments
inform the Technical Documentation team
at an early stage in the process. This includes
the provision of drawings for the spare
parts list and the transfer of function drawings
for the operating instructions. The
whole process takes place approximately
six months in advance. The modular structure
of the documentation allows the changes
resulting from constructional optimisations
for series production to be incorporated
relatively late in the process.
48
49
Technical documentation for
PM machines also available online
This large quantity of data sheets, documents,
and information also has to be processed
and formatted. The average output
of the Technical Documentation amounts to
320,000 pages of A4 per month… In addition
to qualified employees, the Technical
Documentation department is therefore
also home to several high-quality printers
and copiers, and the department is also
involved in collaborative projects with universities.
The documentation accompanying
each individual machine is archived at PM
and remains available for decades into the
future. From January 2007, authorised
Putzmeister dealers will also be able to
access documentation as PDF files online
from anywhere in the world.
50
51
It is an unavoidable fact that concrete
delivery lines are subjected to a normal
level of wear during operation. However,
professionals use a workaround so that
they can use the pipes for as long as
possible.
The most important decision affecting the
life of a concrete delivery pipe is made on
purchasing: If single-layer delivery pipes
(ST 52) are selected, the operator can expect
a greater amount of wear than with
two-layer delivery pipes (standard 2-layer
or Proline models). Regardless of whether
the pump operator has chosen a one or twolayer
delivery line, the wear on the pipes is
never even, but is significantly worse on the
piston side of the pipe. In extreme cases,
this can mean that while the material along
two thirds of the inner wall is still sufficiently
strong to pump several thousand cubic
metres of concrete, the third along the piston
may already be dangerously thin. For safety
reasons, this is the latest point at which the
pipe should be replaced.
However, the concrete throughput, or service
life of a delivery line can be prolonged by
rotating each individual pipe section axially
by 120° three times after approx. 15 to 20 %
of its expected life (concrete throughput
quantity). When the pipeline reaches approximately
the halfway stage in its expected
service life, cost-conscious machine operators
also rotate their delivery line pipes in a
radial rotation. A radial rotation of 180° is
also recommended if the boom pipework
has a 90° bend. By using these tricks of the
trade, you can ensure more even wear of
the concrete pump pipeline and significantly
prolong the life of the pipe sections and
delivery line bends.
Practical Tip
"Life-prolonging" measures
for pipelines
Putzmeister Parts Service supplies specialised
measuring devices for determining the
actual wall thickness of the pipeline. The
two-layer measuring device is recommended
for determining the wall thickness with duallayer
pipelines, while the ultrasound device
is suitable for single-layer delivery pipes.
53
52
21
PM 3833 GB

Application
PUMI ® s – Reliable Partners for
Concrete Transport Plants
Havelbeton GmbH & Co.KG has firmly
established itself on the market alongside
major concrete pumping service companies
in and around Berlin. From its base in
Oranienburg, the company supplies the
region of Oberhavel and the northern
areas of Berlin with fresh concrete,
including pump delivery.
Concreting of six foundations for the new skating rink – a typical job for a PUMI ®
"Of course, the orders do not generate themselves.
This is where I come in, for example,
advising customers and offering economical
solutions", explains Pierre Neumann, Havelbeton
managing director and officer with
statutory authority. The company has been in
business for over 15 years. The company
premises, with its own harbour close to the
Lehnitz lock, is the ideal location for the
delivery of sand, gravel and hardcore for
concrete production, with short transport
routes to the concrete mixing plant. Pierre
Neumann explains: "Since many of the larger
construction companies in this area no
longer exist, we are increasingly focussing
on smaller orders – such as patios, foundations,
base plates, floors, ring beams for
single family houses, etc."
So that Havelbeton customers do not have
to order a separate pump for their concrete,
which is not normally required in large
quantities, the company's vehicle fleet in-
22
PM 3833 GB
cludes PUMI ® truck mixer concrete pumps
with 24-metre booms. Havelbeton decided
on the rotor pump system, a decision approved
by the machine operators and the
business management alike. Driver René
Hennig explains the advantages: "With the
rotor PUMI ® , I can control the dose and
delivery rate very precisely, and a maximum
of one bucket full of concrete residue is left
behind on cleaning." Added to this is the
relatively long life of the rotor tube, the
only wearing part of the pump. Havelbeton
uses hoses of up to 6,000 m 3 for pumping
concrete.
On the morning of my visit, the PUMI ® driven
by machine operator René had installed
a total of 45 m 3 of concrete at Oranienburg's
new skating rink. The 24-m-boom was used
to fill six foundation formworks of different
sizes, and the PUMI ® only had to be changed
once. For the early afternoon, Havelbeton
mixing manager Wolfgang Leszczenski had
Ailing summer houses
on attractive foundations
Since the local authorities in Mühlenbeck
designated the land containing
original dachas official building land,
individual parcels of the popular 1950s
summer houses, mostly only built in
lightweight materials, have been sold
off to private investors. However, the
buildings were in such a poor state of
repair that it was more efficient to rip
them down rather than renovate them.
In place of the summer houses, new
single-family homes have been erected
within just a few weeks (mostly from
prefabricated materials) in this region,
which is popular for its lakes and woodland.
scheduled a visit for the machine to a small
construction site in Mühlenbeck, north of
Berlin.
Here, surrounded by pine forest, two new
homes are being built on the land where a
summer house previously stood. The PUMI ®
machine operator is familiar with the route
to the site from concreting the first base
plate here. Today he will be pouring the
base plate for the second house. Due to the
high water level in the area, many construction
firms have not built foundations
beneath their new buildings. 31 m 3 of concrete
has to be transported to the site, pumped,
and distributed. To do this, Havelbeton
uses two truck mixers together with their
new PUMI ® . Once in position on the future
drive of the house, the machine is easily set
up and supported. "In this location, it would
certainly not be as easy to use truck-mounted
concrete pumps", explains PUMI ® driver
René, positioning the placing boom and
switching on the rotor pump. The job is
complete within 60 minutes, the concrete is
quickly and cleanly integrated, and another
Havelbeton customer is satisfied.
Application
54 55
Fascinated by the Ergonic ® control system of his PUMI ® –
Havelbeton Managing Director Pierre Neumann (Photo: Havelbeton)
The Havelbeton PUMI ® delivers, pumps and distributes concrete for the base plate of a new single-family home in the middle of the forest
56
23
PM 3833 GB

Background
Setting an example
The concrete pump rental service J. Heider
& Sohn GmbH, based in Bodnegg, received
several congratulations in celebration
of the company's 20th anniversary. Many
congratulators brought gifts or presented
the firm with written thank yous for their
reliable cooperation. The company is a
family concern run by Heidi and Norbert
Heider, in which Norbert's brother Josef
(Jr.) also works as a machine operator.
On the occasion of the 20th anniversary,
the gift they were most pleased with was
this drawing in poster format.
The picture was created by 13-year-old
leukaemia sufferer Yvonne and her younger
brother Nico, 11. The children's father is
employed by an associated construction
company, and the Heider family spontaneously
stepped in to offer driving support
when Yvonne's treatment began to require
daily visits to hospital in Ulm, 100 kilometres
away. The family also helped out if
brother Nico needed looking after while
mother and daughter were at the hospital.
The treatment is now complete and
Yvonne's health is restored, although she
remains under regular medical supervision.
The change has been good for the Heiders,
particularly in times when business is becoming
increasingly stressful and deadlines
are shortening. The concrete pump rental
service was founded in 1986 by the late
Josef Heider (Sr.) and his son Norbert.
Heidi Heider has run the accounts and
planning side of the business since 1988.
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
Your fax for further information
■ Would you like more information on certain topics in this edition of Putzmeister Post?
If so, just copy this page, make a cross next to the topics you are interested in and fax
the form to us. We will then send you detailed information immediately.
❏ Truck-mounted concrete pump M 6X ..................................................BP 3621
❏ Truck-mounted concrete pump M 42-5 „RZ“ .................................... BP 3756
❏ BQF 24 and BQF 28 with rotor pump ..................................................BP 3513
❏ PUMI ® truck mixer concrete pumps ....................................................BP 2047
❏ Truck-mounted concrete pump M 52-5 „Multi-Z“ ..............................MT 3231
❏ Truck-mounted concrete pump M 36-4 „Z“ ........................................BP 3180
❏ Stationary MX concrete placing booms ..............................................MT 2059
❏ PUMI ® with 28- and 31-meter-boom ..................................................BP 3702
❏ Truck-mounted concrete pump M 58 ..................................................BP 3544
❏ KOV piston pump with ball valves ........................................................IP 1027
(The couple met when Heidi was working
in a petrol station and Norbert stopped to
fill up his concrete pump). With their two
relatively new M 36-4 and M 28-4 truckmounted
concrete pumps (both based on a
Z-fold system), the pump service mainly
performs jobs for numerous small construction
companies in the Ravensburg
region and throughout the Lake Constance
Putzmeister AG, Max-Eyth-Str. 10, D-72631 Aichtal
PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458
administrative district. Their normal jobs
require an output of around 150 m3 , with
the occasional larger job of up to 500 m3 concrete. Direct contact with most of their
customers makes business all the more
personal.
And, as Heidi Heider explains, "If we can
help out on a private basis now and then,
then we do so gladly".
57
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
Phone +49 ( 71 27) 599-0
Fax +49 (71 27) 599-520
Internet: http://www.putzmeister.de
E-mail: pmw@pmw.de
PM 3833 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. © 2006 by Putzmeister Printed in Germany (3.50612RR)