The Nile Corniche Project in Cairo: One of the largest ... - Putzmeister

The magazine by Putzmeister Holding GmbH 82
Innovative backfilling
of annual space at
pumped-storage hydropower
plant in Vianden
Sewage sludge instead
of concrete: Stationary
boom at sewage treatment
plant in Prague
Putzmeister Brasil
on the upswing
The Nile Corniche Project
in Cairo:
One of the largest construction
projects in Egypt
PM 4432 GB
1

Content Content/Trade fair dates
Title story
The Nile Corniche Project in Cairo:
One of the largest construction projects in Egypt 4
50 questions
How does Putzmeister guarantee the quality of its products? 10
On site
Pumped-storage hydroelectric plant in Vianden / Luxembourg
Rethinking pays off: Innovative solution for
backfilling the annular space in a pressure shaft 12
Jeddah / Saudi Arabia:
Reaching for the sky by the Red Sea 16
System technology
Autocor®
Economical and flexible solution for
supplying concrete to several precast plant buildings 20
Putzmeister Solid Pumps
Sewage treatment plant in Prague / Czech Republic
Stationary boom gone astray:
Sewage sludge instead of concrete 22
In brief
Brasil believes in hydroelectric power 25
Putzmeister Brasil
Committed team in an emerging market 26
Putzmeister Brasil
User-friendliness is paramount:
The innovative control for small concrete pumps 27
Putzmeister Services
Clean and safe concreting 28
Photo credits 2
Imprint / Trade fair dates 3
4
20
Nile Corniche:
Large project in Egypt
Precast plants
are becoming
more flexible
Photo credits:
All illustrations are subject to copyright of Putzmeister
Holding GmbH unless otherwise stated.
10: egypt_map, Public Domain, CIA · 11: Cairo_skyline_panorama,
Wikimedia Commons, licensed under
CreativeCommons licence by-sa-3.0, Staeiou · 12: A_
Boat_in_the_Nile_River, Public Domain, Mo7amedsalim
· 25, 26: www.seu.lu · 33: Saudi_Arabia_map,
Wikimedia Commons, licensed under CreativeCommons
licence by-sa-3.0, Ras67 · 34: Flag_of_Saudi_
Arabia, Public Domain, unknown · 35: Supplicating_
Pilgrim_at_Masjid_Al_Haram_Mecca_Saudi Arabia,
Wikimedia Commons, licensed under CreativeCommons
licence by-sa-2.5 Generic, Ali Mansuri · 36:
Jeddah_Fountatain_1, Wikimedia Commons, licensed
under CreativeCommons licence by-sa-3.0, Mjakhro
· 37: Medina_Road_-_Jeddah_-_Saudi_Arabia, Public
Domain, Ammar shaker · 38: Jeddah-1938, Wikimedia
Commons, licensed under CreativeCommons
licence by-sa-2.5 Generic, courtesy of William Facey
· 55 - 60: Putzmeister Solid Pumps GmbH · 61: Flag_
of_Brazil, Public Domain, Brazilian Government
2 4
12
3 5
22
Sewage sludge:
Stationary boom
16
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Imprint:
Published by:
Putzmeister Holding GmbH
Max-Eyth-Str. 10
72631 Aichtal · Germany
Editing/layout/typesetting:
Petra Montag
Putzmeister Holding GmbH
Printed by:
Offizin Scheufele GmbH & Co. KG
Tränkestr. 17
70597 Stuttgart · Germany
Pumped-storage
hydroelectric plant:
Annular ring filling
gone astray
All rights and technical modifications
reserved.
Despite careful content control we are
not liable for the content of the specified
external websites. 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 Holding GmbH 2012
Printed in Germany (51204)
Saudi Arabia:
Jeddah is growing
higher into the sky
Trade fair
dates
April to June 2012
16. – 21.04.
Intermat, Paris/France
www.intermat.fr
22. – 25.04.
Construction Machinery Show,
Jeddah/Saudi Arabia
www.constructionmachineryshow.com
07. – 11.05.
IFAT, Munich/Germany
www.ifat.de
29.05. – 02.06.
M&T Expo Brasil,
São Paulo/Brasil
www.mtexpo.com.br
06. – 10.06.
Ankomak, Istanbul/Turkey
www.ankomak.com
6

Rubrik Title story Title Rubrik story
The Nile Corniche Project in Cairo:
One of the largest construction
projects in Egypt
In a prime location along the banks of
the Nile on Nile Corniche Street in Cairo
city centre, construction of a building is
currently underway that will eventually
reach a height of 136 m. The complex will
include a five star St. Regis Hotel as well
as exclusive apartments and offices.
The project investor is the globally operating
Qatari Diar Real Estate Investment
Company, which is a 100 % subsidiary of
the state-owned QIA (Qatar Investment
Authority). The QIA from Doha, Qatar is
primarily active in the international investment
business.
The Consolidated Contractors Company
(CCC) was commissioned to undertake
the Nile Corniche project. The CCC is one
of the largest construction companies
operating in the Middle East. Its main
areas of business include oil and gas,
infrastructure projects and complex
large-scale construction projects. The
company headquarters is based in Athens,
Greece; the annual turnover of CCC
in the 2010 business year was approx.
11.19 billion US $.
The overall building consists of three
high-rise towers positioned at close proximity
to one another and arranged in a Ushape.
The basement and the first three
floors share the same structural shell and
form the spacious foyer, conference and
seminar areas in the luxury hotel.
Meeting tight deadlines through perfect
planning
CCC made contact with Putzmeister
through the local dealer IDP as early as
the planning stage.
The concrete delivery process was planned
in conjunction with CPD and took into
account existing plans for the overall construction
process as well as local factors.
Two of the main challenges encountered
when laying the delivery line were the
extremely confined inner city location of
the construction site and the daily placement
of specific quantities of concrete in
order to meet the tight deadlines.
The placement of concrete using a crane
and bucket was quickly rejected during
planning of the construction process.
u The triple towers share the structure
of the building up to the third storey.
The towers on the right and in the
centre will accommodate a luxury hotel,
whereas the left tower will be home to
exclusive offices and apartments.
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Title story
9
10 12
Ä The heart of the Arabic world
beats in Cairo
Cairo ("al-Qā hira" in Arabic meaning
"The Strong One" or "The Conqueror")
is the capital city of Egypt and the largest
city in Africa and the Arabic world.
Cairo is the political, economic and cultural
centre of Egypt and the surrounding
region. The city is home to the Egyptian
government, the parliament, all
state and religious central authorities as
well as numerous diplomatic missions.
Cairo is the most important traffic hub
in Egypt and boasts numerous universities,
academies, theatres, museums and
monuments. The historic centre of Cairo
is a Mecca of Islamic architecture and
was recognised as a World Heritage Site
by UNESCO in 1979.
The main reasons were:
• a limited number of cranes available
due to space restrictions on site
• cranes would be reserved for
essent ial shuttering and reinforcement
work
• unacceptably long concreting times
due to the slow pace of the crane
bucket method, in particular in the
higher stories
Staggered construction of the three
building sections
Since it was not possible to select a central
point for transferring ready-mix concrete
to the stationary concrete pumps
due to the lack of space, CCC planned to
position a BSA 2110 HD stationary con-
t The CCC team on the construction site:
(1st row, from left to right) Mohammed
Nagui, Mohammed Al Areef,
Osama Morris, Nader Ramzi;
(2nd row, f.l.t.r.) Mohamed Elbaz,
Atef Keylani, Sameh Mahmoud,
Atwa Mohammed
The administrative district of Cairo has
7.9 million inhabitants (2008) and the
metropolitan region has about 16.2 million
inhabitants (2009), which is the
second largest in Africa behind Lagos
in Nigeria. Citizens in Egypt are not
obliged to register, however, which is
why the number of specified inhabitants
is extrapolated based on the population
census figures. Unofficial estimates put
the number of inhabitants living in and
around Cairo at 25 million, which corresponds
to almost a third of the total
population of Egypt.
crete pump supplied by a truck mixer
in front of each of the three high-rise
towers. Each concrete pump would then
pump concrete to an MX 36-4 stationary
boom with a reach of 35.1 m.
This staggered construction process
meant that concrete construction work
could progress independently on each
section of the building and potential delivery
problems at one of the concrete
unloading points would not have an effect
on the progress of the other sections
of the building.
Putzmeister Concrete Project Division
once again demonstrated a high level
of expertise when planning and implementing
the project
The experienced engineers from the
Putzmeister Concrete Project Division
(CPD) actively support the local construction
and project managers in planning
the construction and building site
facilities. Successful high rise and tunnel
construction projects as well as projects
involving the pumping of concrete to
great depths demonstrate their level of
expertise.
The Nile is the longest river on the planet
and has played an important role in
the development of civilisation and the
history of Egypt. The fertile land along
the banks of the Nile gave rise to one of
the earliest advanced civilisations. Even
today, the river Nile is of great economical
importance.
The Nile Corniche project is located on
the banks of the river Nile in Cairo nearby
the famous Tahir Square. Hundreds
of typical sailing boats cross the Nile
daily close to the site. Both locals and
tourists regularly use the boats to escape
the hectic metropolis and enjoy some of
the most spectacular sunsets along the
majestic flowing river.
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Title story
The Nile Corniche project
Height of the building
on completion 136 m
Number of storeys 31
Surface area 9,500 m2 Putzmeister machines used
Pumps 3 x BSA 2110 HD
Booms 3 x MX 36-4
CCC sent Putzmeister the planning documents
for the building and a plan of
the construction site in CAD file format
so that the stationary concrete pumps
and MX boom could be integrated in the
building site facilities plan to scale. The
position, ranges and 1.00 x 1.00 m recesses
required for the climbing columns
on the stationary booms were coordinated
with the site management and entered
in the floor plan and section using
a CAD computer program.
11

Title story
Planning of the concrete delivery lines
began once the positions of the concrete
pumps and booms were approved.
CCC personnel set up the site with the assistance
of Ronald Soussan, Putzmeister
Service Engineer, who remained on site
to oversee commissioning of the machinery
and supervise the first few concrete
placements. The concreting team received
intensive instruction in the concreting
processes, initial pumping with
grout, cleaning procedures and the work
required at the end of the concreting
work.
As a result of meticulous forward planning,
all the materials required for the
delivery line, including all the necessary
brackets and accessory components,
were available on site. Installation of the
stationary concrete pump and the construction
and commissioning of the MX
boom started on the first day and progressed
quickly and succinctly.
The local Putzmeister Service partner,
IDP, was on standby for any service
call-outs during the construction phase
and ensured the reliable supply of spare
parts.
The competent planning of the concreting
delivery process, skilled supervision
during the installation phase and
instruction on handling the machinery
from Putzmeister also made a contribution
to ensuring that the concreting work
progressed speedily and was completed
within the deadlines. n
p Stationary concrete pump
BSA 2110 HPD
p Hydraulic boom MX 36-4
u Concrete shut-off gate valve GVHM
13
14
p Transition point between horizontal
and vertical delivery line
15
Ä International Development
Programmes – IDP
International Development Programmes
company, IDP was established in 1974
to become one of the market leaders in
the field of supply and service of heavy
construction equipment and machinery
in Egypt.
For more than 35 years, IDP’s name
has been associated with some of the
industry’s leading manufacturers. As
a sole agent and representative of international
equipment manufacturers
universally agreed upon to be among
the best in the industry, IDP managed
to become a reliable partner, supplier,
know-how and service provider to
Egypt’s base of construction, industrial
and logistics companies. Our deep
knowledge and extensive experience
as well as our reliability, competence
and readiness to serve, all contributed
to making IDP not only a market
leader, but a preferred partner to the
industry’s best performers.
IDP offers a complete and diversified
range of construction and industrial
equipment and machinery. Concrete
equipment, hoisting and lifting, material
handling, earthmoving as well
as road construction equipment and
machinery.
IDP’s diversity and ability to provide
comprehensive solutions has
allowed us to penetrate the market
and become a leader in the field.
This penetration is driven by a
dedicated team of sales engineers
and representatives who are well
trained on all technical aspects
of our scope and can provide the
necessary knowledge to identify the
particular needs of each and every
customer and project. This team is
backed up by an efficient and competent
after sales service department,
the focus of which is customer
satisfaction.
16 17
p The professional IDP team:
(back, f.l.t.r) Khaled Soliman, Salah Marwan, Amr Soliman, Hazem Akil
(front, f.l.t.r.): Hosam Akil, Aladdin Ghondakly, Ahmed Ezz
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Title story

50 questions 50 questions
35
Products · Question 35
How does Putzmeister guarantee
the quality of its products?
A consistent quality management system
ensures that Putzmeister machines satisfy
the highest requirements – no matter
where in the world they are produced.
"Made by Putzmeister" is an internationally
recognised quality label. To ensure
the continuation of this, the company
pursues a strict, globally applicable
quality strategy: All core processes at
Putzmeister are subject to strict quality
criteria. These criteria are binding for
all employees at all locations in all production
companies of the Putzmeister
Group.
As the world's first manufacturer of
concrete pumps Putzmeister obtained
certification in accordance with DIN
ISO 9001 in 1994. This certificate is an
internationally recognised quality label.
Whoever receives such a certificate documents
that he has established a functioning
quality management system. In
addition, in some countries such as China
and the USA it is necessary to provide
additional quality certificates.
Why Putzmeister has itself audited
every year
Auditors from an independent certification
body of the TÜV Cert check each
year whether Putzmeister meets the
standards of DIN ISO 9001. They examine
all quality-relevant processes from
procurement of individual parts to manufacturing
and assembly to the delivery
of machines to customers.
This is important not least because
Putzmeister produces machines which
are subject to defined safety standards.
The company must be able to demonstrate
at any time that it complies with
these standards for each individual
machine.
To find out whether Putzmeister can do
this the auditors mention any machine
number for example. The company must
then show that they know everything
there is to know about this machine:
When was it built? Where? Who worked
on the machine? Who checked the machine?
What customer representative
18
inspected and approved the machine
in the factory? When was it delivered?
What customer is using the machine
at the moment? Where is the machine
now?
The development of each machine
is documented continuously
Putzmeister is able to answer such questions
quickly thanks to this continuous
documentation. The machine documentation
and clear operating instructions
also ensure that the customer can use
the machine immediately and without
any risks. And it should remain like this.
Quality management includes the suppliers.
Suppliers are supported by quality
assurance employees at Putzmeister.
Each individual supplier must prove
that he can guarantee top quality at all
times. If a supplier becomes sloppy,
he is then removed from the list of
Putzmeister suppliers.
Incidentally: Putzmeister doesn't just
do all it can to ensure compliance
with the various quality standards.
The company also helps to set such
standards. The Putzmeister management
team works in cooperation
with several bodies on standardisation,
certification and quality assurance.
Putzmeister was responsible
for the development of the European
concrete pump standard EN 12001 for
example. The company assigned the
chairman of the responsible standardisation
committee in Brussels. n
t This employee measures the contours
of a water tank using a laser system.
p Quality confirmed by documents:
This certificate is evidence that Putzmeister's
quality management system
functions.
u Using this 3D coordinate measurement
machine Putzmeister checks the
dimensions of supplied parts.
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p In the precision measurement room: A quality assurance employee
checks wear parts with a hardness testing unit.
20
21

On site
Rethinking pays off:
Innovative solution for
backfilling the annular
space in a pressure shaft
An additional 200 megawatt turbine is
being installed at the Vianden pumpedstorage
hydroelectric plant in the Luxembourgish
Ardennes, taking the total
of machines at the plant to 11. The installation
requires the construction of a new
cavern including a water pressure shaft.
The power house is located 300 m below
the surface of the reservoir inside
the mountain. The inlet to the pressure
shaft is positioned at the centre
of the reservoir lake. The pressure line
consists of a vertical section approximately
300 m in length with a bend at
the end that brings the line horizontal.
The vertical section of the shaft is the
trickiest part to backfill because the
concrete must be transported to extreme
depths.
Difficult task, innovative solution
The annular space between the vertical
steel pipe in the future pressure shaft
and the rock is backfilled with self-compacting
concrete.
The process for filling the horizontal section
of the water pressure shaft was actually
developed at the ARGE pumpedstorage
plant at Vianden.
p The new Putzmeister method ensures
a high degree of quality even when filling
to depths of 300 m
22 24
p The spread of self-compacting concrete
is approx. 760 mm
t The BSA 1405 E standing on the bank
of the reservoir first pumps the concrete
along a 70 m horizontal line up to the
inlet of the pressure shaft in the middle
of the lake. The image on the left shows
the steel pipe segments that are lowered
into the shaft, welded together and then
backfilled to later form the pressure line.
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12
7
8
6
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11
The power plant at Vianden generates
a rated output of 1096 megawatts
(MW) and is one of the most powerful
pump-storage power plants in Europe.
The power plant was constructed
to provide power during peak
times throughout the day. During the
day, water flows from the reservoir
into the nearby river Our, generating
power along the way, and the water
is pumped back to the top at night
when energy costs are low.
The plant was built between 1954 and
1964, but the planning started as far
back as 1925.
The eleventh turbine M11 is currently
being installed. The construction
work started at the beginning of 2010.
The turbine is scheduled for service
at the end of 2013. The overall cost
of the additional machine 11 will be
somewhere in the region of € 150m.
The necessary extension of the reservoir
will cost about € 10m.
Ä www.seo.lu
4
3
1
2
Technical data
M11
1 Inlet structure 4
2 Vertical pressure line
3 Horizontal pressure line
4 Machine cavern
5 Transformer cavern
6 Auxiliary tunnels
7 Access tunnels 3
8 Underwater tunnels 3
9 Portal structure
10 Outlet structure
11 Machines 1 – 9
12 Machine 10
On site
Pressure shaft
Height of vertical shaft 300 m
Horizontal distance between pump
and inlet to the pressure shaft 70 m
Diameter of the steel pipes 4.8 m
Diameter of the rock excavation 5.4 m
Length of a steel pipe section 12 m
Concrete volume for each constructed
section (12 m height) approx. 60 m³
Concrete cycle per week: 1 x 60m³
Concrete mix type SCC
M11
Nominal drop height (net) 280 m
Nominal flow rate 78.2 m³/s
Turbine output (rated) 194.9 MW
(max.) 203.3 MW
Speed 333.3 rpm
Flywheel diameter 4.3 m
25
26

On site On site
✘Disadvantages
of the conventional
process of backfilling
from bottom to top:
• Danger of losing both delivery
lines through blockages before
the job is complete. Once this
happens, the space can only be
filled using buckets from above.
• The equipment costs are much
higher than the backfilling
process developed by CPD:
more powerful pumps are
required, costs for the delivery
lines are higher
The team from the Putzmeister Concrete
Project Division devised a system for filling
the vertical section from above. If the
traditional approach to concreting pressure
shafts is adopted, the pump is located
on the same level as the power house
and conveys concrete upwards. Usually
two delivery lines (one for delivery, one
as a replacement) are laid in the annular
space and extended as the steel pipes advance.
On completion, the delivery lines
are concreted into the filled void.
✔
Advantages of backfilling
from top to bottom:
• The delivery line (only one
required!) is accessible at all
times. If a blockage forms,
backfilling can continue once
the blocked segment in the
line is replaced.
• A smaller pump is adequate
to complete the job. Only one
machine is required
• More economical and reliable
Putzmeister is breaking new ground
If one considers the disadvantages of the
conventional process of backfilling annular
spaces from bottom to top, such as
losing the delivery line at the end of concreting,
the logical step would be to reverse
the process and concrete the void
from top to bottom. The task is not an
easy one because problems such as concrete
segregation may arise. However,
the team from the Putzmeister Concrete
Project Division has found a successful
solution.
27
The BSA 1405 E stationary pump is located
on the bank of the reservoir lake.
From there, a 70 m horizontal delivery
line is laid across a bridge to the inlet
in the middle of the lake and bends
downwards into a vertical delivery line
secured to the rock wall in the pressure
shaft that leads 300 m into the depths.
The diameter of the horizontal and vertical
delivery line is 100 mm because the
line must offer additional resistance to
prevent segregation and unexpected acceleration
of the concrete that is pumped
downwards.
The pipe installation in the shaft
consists of:
• a vent valve to prevent a vacuum
from developing in the line,
• a pressure sensor that monitors
the fill level of the concrete in the
delivery line and
• a fixture for anchoring the vertical
pipeline.
The following equipment is located at
the site of concrete placement:
• a 3-stage steel platform that is
adjusted (in 12 m increments) as
work progresses. The height of the
platform is adjusted using a cable
winch located in the shaft, which is
secured at reservoir level and connected
to the installed pipe section
via guide rollers.
t The shut-off valves are controlled
automatically
The following equipment is used for
concrete distribution on the platform:
• two hydraulic gate valves GVH,
• distribution equipment,
• one hydraulic power pack and
• one automatic control unit for
the shut-off valve.
The shut-off valve opens and closes automatically
according to changes in pressure
detected by the sensor and controls
the fill level in the line to prevent segregation
and acceleration of the concrete
and ensure steady, efficient backfilling.
Special thanks goes to the staff at the
ARGE pump-storage power plant in Vianden
for their constructive collaboration
and professional support during the
commissioning of the new system. n
Ä Cavern structure M 11
Putzmeister was involved in building
the cavern structure for machine 11:
The company Hans Eibinger – a Putzmeister
agent from Austria – erected
the boom. The pump originated from
ARGE.
The stationary boom on tubular
column MXR 32-4 T and concrete
pump BSA 1408 E located in one of
the access tunnels pumped a total of
20,000 m³ of concrete into the cavern.
The stationary boom was raised to a
final tubular column length of 34 m.
Dimensions of the cavern
Length 52 m
Width 25 m
Height 48 m
p Clear advantage: One stationary concrete pump such as the BSA 1405 E is totally
adequate for this method of filling
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30
Technical data
BSA 1405 E
Max. output 55 m³/h
Max. concrete pressure 106 bar
Drive (electric) 75 kW
Delivery cylinder dia. 200 mm
Piston stroke 1,400 mm
Delivery line
Model ZX 100 HD
Max. pressure 130 bar
Initial length approx. 380 m
(shortened by 12 m after each
steel shell is concreted in place)
28
29

On site On site
Reaching for
the sky by
the Red Sea
Spectacular high-rise buildings are currently
under construction in the Saudi
Arabian city of Jeddah. They will accommodate
luxurious apartments, hotels,
offices and shopping centres at a dream
location along the Corniche Road directly
beside the Red Sea. Putzmeister on-site
representative Bastian Dreher visited
two of the large project sites and spoke
to the respective site managers.
33
Ä Jeddah by the Red Sea …
… is the second largest city in Saudi
Arabia and the gate to Mecca, the holy
city of Islam located about 72 km inland
towards the east. Every year, an
endless stream of pilgrims arrives in
Jeddah, predominantly across the Red
Lamar
Towers
31
34
Sea from Africa and by air from Indonesia
and Pakistan. Unlike Mecca, visitors
of all religions have taken up residence
in Jeddah. Many Africans, Persians,
Turks, Yemenis and Indians all form part
of the local population. Most of them
work in the oil industry.
The Lamar Towers are designed as twin
towers. The taller of the two will reach a
height of 350 m, becoming the highest
building in Jeddah (for the time being at
least). The towers will accommodate hotels,
apartments, shopping centres and
offices covering a total area of 415,500
square metres. The structure will have already
reached 100 m when this article is
printed and the towers are scheduled for
completion in 2013. About 2000 people
are working on the vast construction site.
35 36 37
Jeddah has around 3 million inhabitants
and operates the most important
export port for petroleum products and
livestock (goats, sheep and camels) in the
region.
The city is approximately 300 years old
and has witnessed tremendous development
since 1947: back then, the popula-
Ehab Sobhy Mohamed – site manager
from the construction company Turner
International Construction – talked with
Bastian Dreher, Putzmeister Middle East
about the concreting work that started
in 2008. Four powerful Putzmeister stationary
pumps are on site: 1x BSA 14000
HP-D, 1x BSA 14000 SHP-D, 2x BSA 2110
HP-D and four type MX 32-4 T stationary
booms. A total of 2.5 km of ZX 125 delivery
lines have been laid (of which 1.6
km at 200 bar and 0.9 km at 130 bar).
About 245,000 cubic metres of concrete
are required for the foundation, ceilings
on each floor and remaining structural
elements.
"Based on international experience and
previous projects, Turner decided to use
Putzmeister equipment from the outset",
explains Mohamed. "Subcontractor
SBM (Saudi Building Material) and
Putzmeister machines have kept the project
running on schedule. We have also
received good support from Medco and
Putzmeister." n
tion was only 30,000 and people were restricted
to living within a small area inside
the city walls. The "Corniche" boulevard
lined with hotels and palaces that stretch
along 60 km of Red Sea coastline provides
the best overall picture of exactly
how large the city is. Jeddah is nestled
between the sea and the Asir mountains.
p Podium of the Lamar Towers
pView of the podium and one of the twin Lamar Towers p Model of the Lamar Towers
p The Lamar twin towers will reach a height of about 350 m
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38

On site On site
Headquarter
Business Park
SBM is working on the construction of
Headquarter Business Park at another
large site along Jeddah's Corniche Road.
The floor plan of the unconventional
complex consists of a narrow rectangle
with a comparatively low building
of 13 storeys positioned along the side
overlooking the city. The approximately
240 m, 50-storey tower tapers upwards
and appears to lean towards the Red Sea.
The front of the tower will be partially
constructed from glass that absorbs minimal
sunlight and offers shading properties.
With an efficient power and water
supply, the Headquarter Business Park
will be one of the few environmentally
friendly buildings in Saudi Arabia. The
exclusive offices of numerous company
headquarters will be ready for occupancy
on schedule at the end of 2012 and
the site will offer a total of 1700 parking
spaces.
View of the "Corniche" (promenade)
in Jeddah
42 43
41
SBM started the concreting work in
2009 with two BSA 2110 HP-D and two
MX 32-4 T as well as a ZX 125 delivery
line (130 bar). A total of 105,000 cubic
metres of concrete will be required for
the structure (C60) and the floors (C40),
as well as the large volume of concrete
needed for the elaborate deep pile foundation
because of the water table level
of only 70 cm and numerous voids in the
ground (caused by coral!).
p Complex column geometry p (right to left): Engineer Ahmed Mahmoud Hammad (Project Manager Freyssinet Saudi
Arabia), Bastian Dreher (Putzmeister Project Manager), Qasim Darwish (Medco Sales Manager)
Engineer and project manager Ahmed
Mahmoud Hammad from the construction
company Freyssinet Saudi Arabia
gave details of the concreting work:
"The deep pile foundation alone took
10 months to complete. The anchoring
system for the entire building consists of
360 piles 1.20 m in diameter and 40 m in
length and 267 piles 0.9 m in diameter
and 25 m in length." The placement of
concrete was difficult in some areas, e.g.
the join between the 8th and 9th floor
which forms the transitional point from
the podium to the tower.
Engineer Hammad added "The tapered
shape of the building was extremely difficult
to concrete. On the 42nd floor, a
stationary boom was dismounted from
the sloping side of the building. Not an
easy task."
Hammad is impressed with the reliability
of Putzmeister pumps and concluded
"The customer service provided in Saudi
Arabia is exemplary." n
p BSA 2110 HP-D on the construction site
pu Stationary boom MX 32-4 T on new
tubular column system RS850
u Model of the Headquarter Business Park
q View of the Lamar Towers from the
Corniche Road
44 45
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System technology
Economical and flexible solution with
Autocor® for supplying concrete to
several precast plant buildings
Traditionally in precast plants there are
bucket conveyors or a bucket for filling
the formwork with concrete. If, however,
both a flexible and economical system is
required, the solution using a compact
concrete pump is considered first and
foremost.
Often a bucket conveyor is the link between
the mixer and the concreting
stations in a precast plant. In a smaller
plant generally a bucket is filled and
transported to the formwork by a forklift
or indoor crane. Both systems are indeed
well-engineered, but also have their disadvantages.
A bucket conveyor requires
an elaborate rail system and is therefore
inflexible if for example new concret-
ing stations are added, formworks are
to be filled at alternating locations in
the factory or a new production hall is
constructed. The transport of a bucket
with a forklift or indoor crane is timeconsuming
and obstructs work such as
the transport of reinforcements or finished
elements.
The flexible solution: a transport system
comprising a concrete pump, delivery
line and if necessary a boom. This
can also be useful in connection with a
bucket conveyor. This solution is flexible
because a pipeline can be laid quickly
and simply and thus at peak times for
example makes possible outdoor production
with a pipeline fitted temporarily.
The delivery line is laid underneath
Stationary concrete pump Autocor
1005 E AC with buffer storage and DVH
gate valve. In this precast concrete
plant it delivers 9 m³ of concrete per
hour, approx. 60 m³ per day.
48
the ground in a duct for space-saving
reasons or secured to the hall wall at
the side. If concrete is delivered to various
production halls, gate valves (DVH)
are used. The operator switches the gate
valves to the corresponding position using
the remote control. Normally there
is a sequential process, i.e. a concreting
station is supplied with concrete until all
the formworks are filled, then a switchover
to the next line is effected. If the concrete
has a corresponding setting time,
two concreting stations can be supplied
alternately.
A gate valve, however, has another key
function. After all formworks are filled
at the concreting station, the gate valve
must be drained and cleaned, of course
without interrupting production.
Cleaning
Cleaning connections are already filled
with sponge balls and mounted at the
gate valve at the concrete preparation
stage. If the concreting is completed at
the first location, the gate valve switches
over to the second line. Concrete can
be delivered to the next concreting station
without interruption to production.
At the same time, the cleaning connections
are now positioned in front of the
first hose. A collection container is connected
at the end of the delivery line for
the sponge balls. Using compressed air
the sponge balls are pushed through the
line towards the formwork and push the
concrete from the line, which can almost
be used completely. If the sponge balls
are pushed through the entire line, they
are held in the collection tank. The compressed
air behind them cannot escape.
The line can be depressurised at the
drain cock of the cleaning connections.
49
p The delivery line can also be laid under
the ground to save space. The duct
cover plates are not visible in the image.
Longer delivery lines must be cleaned
using water as high pressure can cause
the concrete to "push through". For example:
A 100 m line with a diameter of
125 mm is filled with approx. 2,900 kg
of concrete.
The entire delivery line does not have
to be filled with water, but a "cleaning
package", comprising a sponge
ball / water / sponge ball or pig, can be
pushed through the delivery line using
compressed air. The clean separation of
the media between concrete and cleaning
water is important so that no blockages
occur during the cleaning process.
The water remains in the pipeline and is
pushed back into a collection tank connected
beside the concrete pump using
compressed air. No water escapes into
the production hall. The delivery line is
empty and clean.
Due to their minimal spatial requirement,
concrete pumps can be easily retrofitted
and/or adapted to modified production
processes in the case of renovations to
production plants. Putzmeister provides
support during the process planning
stage and ensures smooth, long-term
and economical production. n
System technology
50 51
p The concrete flow is distributed to two
delivery lines with help of a DVH gate
valve. The prepared, already connected
cleaning connections can be seen in the
image.
Ä Advantages of Autocor®:
• Continuous and clean
delivery of concrete
• Suitable for all pumpable
concrete and self-compacting
concrete
• Delivery rates up to 53 m³/h,
delivery range over 200 m
• Loading possible directly from
the mixer by a bucket conveyor
or truck mixer
• Clean production channels
• Higher productivity
• Improved utilisation of operating
equipment, area and crane
t Knecht in Metzingen, Germany
uses Autocor® for the manufacture
of its high-quality concrete prefabricated
parts.
u A collection tank holds the sponge
balls at the end of the delivery line.
q The cleaning connections are
filled with sponge balls or pigs and
connected to the gate valve before
concreting.
Compressed air or water is used for
draining and cleaning the delivery
line.
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54

Putzmeister Solid Pumps
Boom arm gone astray:
Sludge instead of concrete
The sewage treatment plant in the city of
Prague, Czech Republic operated by Veolia,
is equipped with four centrifuges for
draining the accumulating sludge. The
sludge is loaded onto a truck and taken
to the dumping ground. This amounts to
75,000 tons of sludge each year.
In the past the sludge was transported
to the storage silo using a screw conveyor.
The wear and the maintenance
costs were so high that the city of Prague
decided to pump the drained sludge directly
into truck containers using Putzmeister
piston pumps and a modified
stationary boom.
The dewatered sludge comes out from
the centrifuge building via a singleshaft
screw conveyor into the pump.
The sludge has a temperature of approx.
50 °C and dry matter content of approx.
30 % TS.
The sludge is stored in a temporary shaft
before it is supplied using the powerful
feeding equipment with a double hydraulic
drive of the solids pump, type
KOS 1050 HP.
Use of pumps with S-transfer tubes
Of all the different types of Putzmeister
pumps only the KOS pump is worth
considering for this application. The
pumped material is hot and viscous. It
may also contain foreign matter which
may pass through the large, open crosssections
of the S-transfer tube unobstructed.
For other pump systems the
special characteristics of the material
may cause a process fault or even destroy
the pump unit.
Boom with fully automatic system
The space-saving and low-profile design,
in comparison to the silo, plays a
decisive role in the use of the boom for
loading sludge into the container. Each
container is set up at a fixed position
for loading. The sludge is distributed
automatically to the container. Sensors
share the status of the container with the
boom over which it is located:
Putzmeister Solid Pumps
55 56
p Schematic diagram of the system:
The stationary boom can easily reach each
point on all six containers. Alternatively the
sludge, also in the silo, can be conveyed to
the direct truck loading unit (right).
• Container at station Yes / No
• Container lid open Yes / No
• Container empty Yes / No
• Container full Continue to the
next container
The fully automatic system of the boom
also keeps the dumping angle of the
drained sludge in the container as small
as possible.
The solids pumps and the boom are activated
via a control system on-site which
is linked to the central control station.
p The boom automatically finds the container to be filled. After roughly 5 hours the
25 cubic metre volume is full.
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Putzmeister Solid Pumps In brief
p The two KOS 1050 HP pumps are loaded with sludge by single-shaft screw conveyors
q The material that is difficult to pump requires more robust pipeline technology
58
Heated control cabinets
and hydraulic unit
Control cabinets and hydraulic units are
heated due to the cold winters in Prague.
The 55 kW sound-proof unit supplies the
piston pumps with energy.
Leak-proof: ZX delivery line
The delivery line is designed with the
tried-and-tested ZX coupling system.
There are positive connections between
the flanges. The delivery line is leakproof
between the two flange elements
via the box coupling and the O-ring and
can be opened very quickly in the case
of a blockage in comparison to a DIN
line.
The two solids pumps convey the sludge
via the pipeline and Y-branch into the
truck loading silo or to the boom arm.
The Y-pipe is very solid and even has a
lifetime guarantee so that this branch
pipe does not crack or burst.
The pipeline is optimally fixed for reliable
continuous operation. There is a
hand valve behind the electric ball cock
for sampling or draining the pipeline after
cleaning. n
59 60
Clear victory for delivery in
closed pipelines
The old sludge transport unit via
screw conveyors with the classic
problems of this technology: Sludge
leaks
Brasil is the third largest producer of
hydroelectric power in the world behind
China and Canada.
The national energy authority of Brasil
(ANEEL) is responsible for granting
approval for the construction of hydroelectric
power stations. The procedures
in small hydroelectric power
stations (Small Hydropower Plants =
SHP) are more simple compared to
those of larger power stations, not
least to distribute power more quickly
and efficiently. The government has
offered contractors financial incentives
such as free permission to develop
on land to promote the construction
of SHPs.
A so-called SHP generates between 1
and 30 MW and requires a reservoir
with a surface area of less than 3 km².
These small power stations often supply
energy directly to the national
grid.
The total power output generated by
SHPs installed in Brasil has tripled
over the last 7 years. In 2010 the figure
reached 3,428 MW – 32 power
stations each contributing between 10
and 30 MW were commissioned this
year alone, adding an extra 470 MW of
power to the overall national output.
The Brasilian state of Minas Gerais
has witnessed 100 SHP projects, the
largest number in the country.
Brasil believes in
hydroelectric power
Hydroelectric power station SHP Unaí Baixo
Location Preto River
Town Unaí/Minas Gerais/Brasil
Output 21 MW
Construction started November 2010
Construction completed December 2011
Building contractor PSO Engenharia
www.psoengenharia.com
Concrete volume 35,000 m³
of which, pumped concrete 31,000 m³
Poured concrete
per block approx. 1,000 m³
M 28 operating reliably at the
Unaí Baixo hydroelectric power station
[Putzmeister Brasil, Dezember 2011]
The head engineer of the construction
company PSO, Rodrigo Pinto de Souza,
was impressed by the power of the BSF
28Z-12L concrete pump.
He highlighted the following points:
• Flexibility of the boom
• Maximum output of 90 m³/h
• Easy operation
• Low maintenance costs
• Service from Putzmeister on-site
during the initial phase
The company PSO wants to enlarge its
fleet of concrete pumps for future projects
to include additional Putzmeister
machines with 28 and 36 m booms. n
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In brief
Putzmeister Brasil –
Committed team in
an emerging market
Putzmeister Brasil currently manufactures
eight different models of Thom-
Katt, BSA, CityPump and BSF. Great
importance is attached to high manufacturing
standards, good service and
customer proximity.
Customers within the country benefit
from the local manufacture of
Putzmeister machines in a unique
p Well stocked spare parts warehouse for all Putzmeister machines
q Twelve machines roll off the production line each month
way because they are able to take advantage
of the low interest rates offered
by the state-subsidised financing program
FINAME.
The Brasilian ThomKatt and CityPump
models are equipped with the new SPC
(Small Pump Control) and OPS (Open
Pump System) control.
63
64
61
Small Pump Control for Open Pump Systems
(SPC-OPS) is a colour display that
incorporates a control with integral input/output
and engine control interface.
The software was developed for open
hydraulic circuits, but it is also used for
the closed circuits of the BSA and City-
Pump models in Brasil. The compact,
inexpensive design of the universal SPC
control cabinet is integrated in all trailer
concrete pumps from the ThomKatt and
BSA range as well as the mobile City-
Pumps manufactured by Putzmeister
Brasil. The advantage of the cabinet is
that the operator does not have to adapt
himself to changes when switching from
a TK 70B to a CP 60B.
A powerful processor and a 4.3" colour
display reduce the number of faults and
enhance system functions such as the
start-up performance, pumping sequence
control, central display of information
and so on. The user is assisted during
operation and fault diagnosis. The display
control is easy to operate and existing
functions from larger Putzmeister
truck-mounted concrete pumps such as
the Switch Over Delay (SOD), Push Over
Hydraulic (POH) and Ergonic Output
Control (EOC) are also integrated here.
Functions
The layout of the new SPC control makes
it easier to connect input and output signals
for the hydraulic pump control and
can be extended as required. The control
is fault-tolerant, generates and displays
additional information such as the oil
temperature, engine operating hours,
pumping sequence, fuel consumption
and the number of strokes per minute,
and adapts to the most varied of site
conditions.
The SPC control has a series of displays
that assist the operator, i.e. information
about local switches, switches on the
cable remote control, sensors and data
is retrieved and malfunctions are shown
on the colour display. Furthermore, the
"Help menu" provides additional information
and explanations in the relevant
national language. Faults on machines
located on site are rectified much more
quickly and easily compared to other
controls for trailer concrete pump avail-
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able on the market. The information
that appears on the display is exported
to facilitate easier remote diagnosis via
telephone. In the unlikely event that
the display control fails, a new one can
be sent to the PM customer within 24
hours. Customers can unplug the old
control and attach the new one by
themselves easily by "plug-and-play".
Innovation
User-friendliness is paramount:
the innovative control for small
concrete pumps
t The home menu on the SPC control
q Successful model in Brasil:
ThomKatt TK 70 B
In brief
The display on the SPC control can be
adapted individually to existing options
and equipment features on the
machine, e.g. circuit symbols or symbolic
representation of the hydraulic
control.
The main advantage of the new colour
display is the graphic illustrations,
which include symbols and text. The
integral engine monitor, drive speed
monitor and control with a feature that
reduces the fuel consumption (with
Diesel engine) increase the benefits for
the user. As a result, machine operation
is simpler, the machine and pumping
sequence are easier to understand
and the quick, direct analysis of faults
and machine statuses enhances the
overall performance. n
67

Putzmeister Services information:
Clean and safe
concreting
68 70 71
69
EQV valve
• robust and flexible
• pneumatically
operated
• closes reliably
Protective
sleeve
with Velcro
fastener
• lightweight
and clean
• no risk of injury
on the coupling
Concrete
brake
• full, even flow
• no splatters
• quick assembly
• also for 100 mm
and 125 mm
end hoses Proven time
More information is available from:
Tel. +49 (0) 7127 599 289 · spareparts@putzmeister.de
and again!
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