77 customer magazine by putzmeister concrete pumps gmbh

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PM 4276 GB

Customer magazine by Putzmeister Concrete Pumps GmbH

Long-reach boom pumps andbulk material conveyors atpower plant construction site

PM pumps and service in Russia

The RoLine pump concept

Shotcrete placement in 32kmlong, high-altitude tunnels

42534_br_Putzmeister_Post_77_GB_PM-Post Nr.77 GB 07.12.09 12:05 Seite 1

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Contents

Foreword

Power plant construction

TITLE STORY – Long-reach boom pumps and bulk material conveyors at power plant construction site

Food for the Telebelt® – Bulk concrete for dam project

High-rise construction

Clever boom solution

PM elephants in the land of the Russian bears

Bridge construction

Long-reach boom pump at the Unstrut valley bridge

Service

Also in Russia: “PM expertise near you”

Excavation

Pumping for all it’s worth

BSA pumps concrete S.O.B. piles in Trinidad

Background

EU imposes stricter inspections on imported construction equipment

Technology

The M 47-5 in practice

Growing within its niche – the Roline pump concept

Tunnelling

Shotcrete placement in 32 km long, high-altitude tunnels

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Imprint

Editor: Putzmeister Concrete Pumps GmbH Max-Eyth-Straße 1072631 Aichtal / Germany

Editorial department: Jürgen Kronenberg Putzmeister Concrete Pumps GmbHMax-Eyth-Straße 10 72631 Aichtal / Deutschland

Layout & Print: Offizin Scheufele GmbH + Co. KGTränkestraße 1770597 Stuttgart / Germany

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Foreword

2009 is drawing to a close – a difficult yearthat has been like no other in the 51-yearhistory of Putzmeister. The global economiccrisis has affected us greatly, as it has you.Concrete consumption and the quantity ofpumped concrete, which is so important forus, have declined globally – to a greater orlesser extent, depending on the country.Taken as a whole, the decline has been dra-matic and we are all working hard to adaptto the new situation.

All the same, Putzmeister has demonstratedthis year that it is possible to adapt success-fully. After many years of growth, we wereable to apply the brakes in good time. Butthis braking manoeuvre was not easy,because it meant parting with many thingsthat we had come to cherish and even manythat we believed were absolutely necessary.Putzmeister started a restructuring projectfor the entire group at an early stage, whichstreamlined the structure of the companyconsiderably and allowed it to adjust to thenew requirements.

The reduction of the number of employeesin Germany is taking longer than originallyenvisaged due to the agreement that wasamicably reached with the works counciland trade union and, under the currentframework conditions, will not be completedbefore the 1st quarter of 2011. However, the reduced working hours regulations inGermany are enabling capacities to beadjusted until then with considerably re -duced costs for the company.

Since September, the restructuring has been actively moved forward by NorbertScheuch, who was originally ManagingDirector of Putzmeister Holding and who is now Managing director of PutzmeisterConcrete Pumps GmbH. He has many yearsof experience of successful restructuring incomparable companies. With his support,we are implementing the necessary meas-ures in line with the plan that was drawn upin the spring. The key points of this planhave proven themselves in the last sixmonths. Even though our forecasts havebeen considerably lower than those of the

Dear customers and friends of Putzmeister

previous positive years, this has enabled us to ride out the turbulence of the start ofthe year and bring some stability back to the markets we operate in – even if it is at amuch lower level.

At the same time, there has been anincrease in spare parts turnover that ourcustomers are achieving with increasingnumbers of orders. This is also confirmed in the many meetings that Putzmeisteremployees have held on customers' premis-es throughout the year and which fortu-nately are increasingly resulting in sales. As well as the attractive conditions for newmachines, these customers are frequentlyalso taking advantage of the wide range of high-quality used “Putzmeister ValuePumps” in order to enhance their fleet inlight of the current favourable conditions orto open up new markets with specialmachines. Please visit www.putzmeister.de/value-pumps for information about Putz -meister used machines.

At the end of the year, however, we are also looking to the future and 2010, whichwill provide us with the highlight of the construction machinery trade fairs, Bauma,

in April. This time, India – which representsone of our largest growth markets – hasbeen selected as the partner country. We arealready looking forward to welcoming you to our stand in Munich, which will be in theusual spot. There, we will have the oppor-tunity to discuss with you new products,experiences, market trends and generaldevelopment. We are already looking for-ward to it.

I wish you and your family a peaceful andcontemplative end to the year and all thebest for a successful 2010.

Your

Dr. Ralf v. BaerChairman of the Management BoardPutzmeister Concrete Pumps GmbHPutzmeister Holding GmbH


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Power plant construction – Title story

The client has commissioned ALPINE BauDeutschland AG (Industrial and Power PlantConstruction, Dortmund branch) with theexecution of the extensive earth, concreteand construction work for the two newpower plant blocks “D” and “E” (order volu-me EUR 135 million). The two-block powerplant with 2 x 800 megawatt power is beingconstructed on the site of a previously plan-ned nuclear power plant and next to thehigh temperature reactor THTR-300, whichhas been shut down since September 1989.

RWE Power AG in Hamm, Westphalia, is investing around EUR 2 billion in the construc-tion of one of the world’s most efficient coal power plants with a total output of 1,600Megawatts. The placement of around 250,000 m³ concrete of different property classesand consistencies is predominantly carried out using Putzmeister truck-mounted con-crete pumps with up to 62 m placing boom height and two stationary PM placing booms.But a Telebelt® TB 130 telescoping conveyor belt is also used on the vast constructionsite to deliver the different bulk materials.

The construction of the new power plant in-cludes a building complex of engine and boilerhouses, switching system buildings and watercentre, four stair towers, seven silos with up to 10,000 m³ capacity for limestone, cementand ash as well as two 165 m high coolingtowers.

Fleet mix crucial

The order to deliver over 220,000 m³ of con-crete was received by the concrete pumpingservice BEKA in Kerpen. Crucial in theassignment was the fleet composition of the

Long-reach boom pumps and bulk materialconveyors at power plant construction site

pumping service, which consists of over 40 truck-mounted concrete pumps. Thus, inaddition to machines from the 20, 30 and 40metre class, BEKA also has three M 52-5s,three M 58-5s and two M 62-6s. Due to thevast boom lengths and large working range,made possible by flexible 5 and 6 arm tech-nology, BEKA’s long-reach boom pumpsgave it a crucial advantage in the invitationto tender. In addition, there was the possibi-lity of supporting the large 5 and 6-axletrucks in OSS mode on one side, if the con-struction site conditions allow for this.

The two M 58-5 and M 62-6 (bottom) Beka long-reach boom pumps concreting one of the huge bottom plates of the power plant inHamm, Westphalia (Photo: Alpine)

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Machine operator enjoys the extras

The extensive concreting began in spring2008. For the production of the bottom plate, which is 5 m thick in places, up to6,500 m³ concrete (C35/45) were integratedwet in wet. To complete the numerous walls,floors and beams, the Putzmeister pumpsare used here almost daily. On one of ourvisits, we met BEKA machine operator RiccoLemm, “My M 58 is equipped with all theelectronic extras offered by Putzmeister,such as familiar systems like EBC, EOC, EPS.If you – like me now – are standing on scaf-folding at a height of 20 m, the additionalfunctions are practical, such as being able toswitch the vibrator on the hopper on and offby radio remote control, and then the gra-phical display on the remote control showsme all the important information at all times– down to the current fluid temperature!”

Ricco Lemm is often at the power plant con-struction site with the M 58-5. Today he ispumping concrete with a 16 mm maximumparticle size (C30/37) into the wall form-work of a switching system building. Due tothe narrow reinforcement, he has switchedthe bottom part of his 2-part end hose for atapering and an 80 mm end hose piece. The

squeeze valve – also activated via the radioremote control – remains connected to the“1 metre piece”, the upper part of the splitend hose. When the boom is swung over theformwork, the valve squeezes the end hosetogether with compressed air, so that noconcrete remains inside.

There’s not much space – but the M 62-6 can still be supported correctly

Boom tip with squeeze valve, tapering andend hose over the reinforcement

Everything in sight and easy to use: The modern PM radio remote control with graphical display

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Stationary boom grows to 55 m heightwith lattice tower

An interesting interaction between truck-mounted concrete pumps and stationaryconcrete placing booms can be seen duringconcreting of the power houses: The two PMstationary booms with 32 m horizontalreach are supported on a tubular column, oron a lattice tower, which is extended to up to55 m in height as the construction progres-ses. Via a special tube support system, thedelivery line is secured on the lattice tower.It is supplied with concrete at the bottomend by one of the BEKA truck-mounted con-crete pumps.

Both the outer walls of the four stair towers,which are up to 120 m high, and the seven

silos, which are up to 70 m high, are con-structed using the sliding formwork proce-dure. It is important when concreting withsliding formwork that the concrete composi-tion is adapted to the respective outside tem-perature and sliding speed. Dipl.-Ing.Andreas Michnik, head of work preparationat the construction site said: “As the concre-te is placed round the clock here, but onlyrelatively small placement jobs are re-quired, we work with a crane bucket. Whenusing pumps, the concrete would otherwiseset in the long delivery line!”

EBC (Ergonic Boom Control):Controls, regulates and limits, as re-quired, the movements of the concreteplac ing boom. EBC actively damps thevertical movements of the boom, simpli-fies operation and supports safety duringconcrete placement.

EPS (Ergonic Pump System)Regulates the concrete pump control fullyelectronically in the interest of optimiseddelivery. Data, such as delivery pressure,delivery rate of the hydraulic pump,hydraulic pressure and many othersignals, is actively co-ordinated. With EPS,the machine operator can assign and limitthe maximum desired pump pressure, forexample, (important for delivery lines,whose compressive strength or wear con-dition is not known, or for “sensitive” form-works). Even switching over the transfertubes from one delivery cylinder to theother is adapted to the current concreteconsistency and avoids “thuds”.

EOC (Ergonic Output Control)Ensures fuel-efficient operation of theconcrete pump. The EOC automaticallyregulates the optimal engine speed forthe respective delivery rate. This reducesconsumption, lowers wear and reducesnoise

EGD-RC (radio remote control with graphical display)With this ergonomic control system, allEBC functions can be operated – even theupper and lower limits of the working spa-ce can be defined, as well as the movementof the rotating mechanism. On the display,the machine operator receives additionalfeedback and system indicators from themachine, such as engine speed, fluid tem-perature, concrete pressure, delivery rateand information on pressure and volumelimitations. The vibrator and end hosesqueeze valve too can be switched on andoff via EGD-RC.

During construction of the power houses, two stationary PM placing booms distribu-te the concrete. One from a lattice tower, the other supported on tubular columns(as shown here) (Photo: Alpine)

Stiff concrete with increased strengthis the “daily bread” of PM pumps

The sensitive radioremote control meansthe boom tip with end

hose can be guidedaccurately

Attractive Ergonic modules

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New coal power plant with exemplaryhigh efficiency

The two new power plant blocks of RWEPower AG in Hamm-Uentrop will be firedwith coal and petrol coke. With an efficien-cy of approx. 46 %, the new two-block plantwill be one of the most modern and efficientcoal power plants in the world. Blocks “D”and “E” should be connected to the grid bythe start of 2012, and blocks “A” and “B”which have been in service since 1962/63(output per 160 Megawatt) will be shutdown.

For more information, see:www.rwe.comwww.alpine.atwww.bekabeton.dewww.euro-hochweit.dewww.wikipedia.de

TELEBELT® delivers dry tamped concreteand bulk material

While you come across PM truck-mountedconcrete pumps at the power plant con-struction site in Hamm almost daily duringthe carcass construction phase, most of thePutzmeister Telebelt® TB 130’s jobs are com-pleted by now. The TB 130 is a mobile con-veyor belt system, which conveys unpump-able, pourable bulk materials into the site ofconcrete placement via a telescoping con-veyor belt. Typical materials include exca-vated material, hardcore, sand, humus, barkmulch, granulate or extremely stiff, onlyearth-moist concretes. Here at the powerplant construction site, the Telebelt® – beforeinstallation of the cleanliness layer and theconstruction concrete – had conveyed dryfilling and tamped concrete (consistenceclass F1) as well as sand and hardcore into

the various pits. The building materialswere initially passed onto the Telebelt® feedconveyor either by truck mixers, truck tip-pers, mobile excavators or wheel loaders, inorder then to be transported up to 39 malong the main telescoping conveyor beltand distributed with precision. The beltmovements and the delivery rate are con-trolled by radio remote control, similar tothe control of the PM truck-mounted concre-te pumps. Even a slanted raising or loweringof the delivery belt is of course possible. Theactual installation performance of the TB130 depends on the type of bulk material,the construction site logistics, the waitingtimes between the batches, etc. The Telebelt®

is designed for an output of up to 270 m³/h(max./theor.). ALPINE Bau Deutschland andthe subcontractor DÜCHTING hired theTelebelt® from Euro-HochWeit AG (Waltrop).

The Telebelt® conveyor belt can be telescoped several times and enables precision placement of material (Photo: Alpine)

Filling the pit with the telescoping TB 130 Telebelt® conveyor belt. The reach with thismodel is 39 m (Photo: Euro-Hochweit).

Truck mixers pass the tamped concreteand other bulk materials onto the Telebelt®

feed conveyor (Photo: Euro-Hochweit)

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The PM Multiboom with a reach of 24 m usually sits on a truck-mounted concrete pump – here,however, “for a change”, it sits on a self-climbing tubular column (Photo: Heidelberger Beton)

By means of a riser, the boomless truck-mounted concrete pump with MXR Multi-boom is now connected to the highest floor (Photo: Heidelberger Beton)

Andreas Keiser, Heidelberger Beton

Clever boom solution

In the centre of Berlin, one of the most pro-minent construction gaps is currently beingclosed: Not far from Alexanderplatz, as anarchitectonic eye-catcher, the “Königstadt-Carree am Alexanderplatz” is being con-structed as the new north gateway to Berlin’smost famous square. Heidelberger Beton,north-east concrete pumping division, is con-creting the upper stories with a PutzmeisterMXR Multiboom, which can be separatedfrom the truck-mounted concrete pump.

Lack of space requires separate solution

At the junction of Mollstrasse and Otto-Braun-Strasse, the construction works for a71 m high office block with 21 floors, flankedby a doctor’s clinic and a hotel, have beenunderway since 2007. Heidelberger Beton

together with Berger Beton on behalf ofDresdner Industrie- und Wohnungs bau -gesellschaft mbH has supplied the ready-mixed concrete. During the pumping work,there has been a special feature, whichAndreas Keiser, deputy division manager ofHeidelberger Beton GmbH, describes as fol-lows: “From the 9th floor, we were no longerable to work with our truck-mounted concre-te pumps due to a lack of space. The accessstreet in front of the construction site and theinner yard were simply too narrow. Instead,we removed the placing boom (MXR 24) fromthe truck-mounted concrete pump and hadthe boom climb upwards hydraulically on an18 m high tubular column in the course ofthe construction.” A securely laid riser thensupplies the respective highest story withconcrete via a high pressure pump.

Multiboom for mobile and stationary use

The MXR Multiboom was developed byPutzmeister for pumping services whichplace particular value on a flexibly deploy-able machinery fleet. For if the carcassesbecome so high than they can no longer bereached by the boom of a truck-mountedconcrete pump, the 4-arm multiboom toget-her with adapter can be removed from thetruck and set up on a tubular column. Thismeans the truck-mounted concrete pumpplacing boom becomes a stationary boom,which is either firmly installed on a tubularcolumn with cruciform base or – as here atthe “Königstadt-Carree” construction site –moves from floor to floor as the constructionprogresses with the help of an automaticclimbing system. Between the concretingworks, the Heidelberger Beton pumping ser-vice deploys the carrier truck with the con-crete pump on other construction sites.During these times, concrete delivery is car-ried out using pump tubes or pipelines – thetruck-mounted concrete pump, which nowno longer has a boom, carries 60 m of suchpipes with it on board.

For more information, see:www.deutsches-architektur-forum.dede.wikipedia.org

Even if space for truck-mounted concre-te pumps is tight on construction sites –there are solutions! So, for example, theBerlin pumping service of HeidelbergerBeton, shows how a placing boom andtruck-mounted concrete pump can be setup separately in the tightest of spaces inthe centre of the German capital andnonetheless be operated together. Largetruck-mounted concrete pumps wouldhave no chance on this construction site.


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5-arm booms are simply more flexible: Here are two Putzmeister M 52-5s, which notonly reach high, but with their arm (“flyer”), also reach horizontally across the formwork

Long-reachboom pumpat the Unstrutvalley bridge

In addition to three tunnels, the route alsorequires six large bridge constructions, oneof which is the Unstrut valley bridge, which iscurrently under construction. At a length of2,668 m and a height of up to 49 m, it is thesecond longest railway bridge in Germany.The structure consists of a chain of 580 mlong, jointless and bearing-free frameworkbridges. The pre-stressed concrete box secti-on, with approx. 5 m construction height and14 m width, is split into 46 sections. Thebridge superstructure is supported by 41piles in a 58 metre pattern as well as by fourreinforced concrete arches. The customer isDB Projektbau GmbH, and construction isbeing executed by a consortium of Alpine Bau Deutschland AG, Leipzig/Halle branch

(management) and Berger Bau GmbH, Berlin.The concrete pump services are being pro -vided by the Putzmeister customer concretedelivery union, Raßnitz.

Quintuplet booms use net reach even inhigh-rise construction

During our visit at the start of September, thepre-stressed concrete box section (trough) wasbeing concreted at the first bend. To place theconcrete accurately in the reinforcement atthis height, a long-reach boom pump with thenecessary vertical reach is required. As shownon the photo, this is only possible with flexible5-arm technology. Truck-mounted concretepumps with 4-arm placing booms with the

same reach would have to have been removedagain without having achieved anything.Stefan Klöpfel, managing director of BFU said,“We are working on both sides of the bridgesuperstructure with two Putzmeister M 52quintuplets, because these machines canunfold their last boom arm over the formworkeven at such a height.”The superstructure between the bends is con-creted using a launching gantry and the asso-ciated formwork. On the lateral brackets, twostationary placing booms with 24 m reachhave been set up on the launching gantry.They are also supplied by truck-mounted con-crete pumps.

For more information, see:www.db.de

As part of the Deutsche Einheit trans-port projects, Deutsche Bahn AG is work-ing full speed ahead on completion ofthe new InterCityExpress (ICE) line fromLeipzig/Halle to Erfurt (VDE rail no.8).This is also part of the planned transeu-ropean high-speed network from Berlinto Verona. PM long-reach boom pumpswith flexible 5-arm technology carry outconcreting work during bridge construct -ion at heights of nearly 50 m.

Bridge construction

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PM elephants in the land of theRussian bears

Large-scale residential complexes as aroutine job

The high-quality residential complex LosiniyOstrov Eco Park is situated on the north-eastern outskirts of Moscow and borders onthe Losiniy Ostrov National Park. The pro-ject, which was started in 2006 and will pro-vide approx. 100,000 m² of living space, isbeing managed by the construction compa-ny Don-Stroy. It consists of five high-risebuildings with up to 30 stories and approx.100 m height of construction. Don-Stroy isworking on the various construction phasesusing a total of three BSA 14000 stationaryconcrete pumps and five PM MX 32-4 climb-ing booms. PM truck-mounted concretepumps with M 36-4 and M 42-5 placing boomsare also involved in pumping a total volumeof approx. 35,000 – 40,000 m³ of concrete.

Alongside six concrete plants and 40 truckmixers, Don-Stroy has a comprehensive ran-ge of construction machines with its own

For many years, Putzmeister was repre-sented in Russia “only” via a sales office.But for four years now, the PM elephantshave been represented by a subsidiary:PM RUS. The reason for opening a dedi-cated branch in the largest country onearth is the high economic growth that isexpected in the BRIC countries (Brazil,Russia, India, China) in upcoming years.And despite the economic difficulties,which have seriously affected Russia likeother countries, there are still someinteresting large-scale projects here –albeit delayed.

pumping fleet. The head of pumping on theconstruction site Alexandr Salmatov ex-plains to us that the short distance betweenmixing plant and construction site meansthat concreting with this project can beachieved during the day. It is otherwise nor-mal in the Russian metropolis to carry outlarge-scale concreting operations in theperiod after the evening rush-hour.

Don-Stroy has handled many large-scale pro-jects such as this over the years. This is whythe use of the stationary concrete pumps onthis construction site is nothing unusual.Alexandr Salmatov merely points out thatone BSA 14000 is being used for two resi-dential towers. His company has reliedexclusively on Putzmeister for many yearsfor quality reasons. And with great pride hesays: “We rarely need the Service depart-ment, because we know the machines sowell that we are able to carry out mainten-ance work and repairs ourselves.Nevertheless, the Putzmeister engineers arealways dropping by, and we discuss withthem alternative solutions for meeting thevarious requirements involved in high-risepumping.”

Carcass of one of the high-rise buildingsin the Losininiy Ostrov Eco Park

For concrete placement, Don-Stroy relies exclus ive for high-rise construction

View of the old and new Moscow. In the centre of the picture, on the right-hand side of the Moskva River, is LomonosovUniversity. On the opposite riverbank, some new “Moscow City” buildings.

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Stationary boom and pumps for the “Moscow City” project

“Moscow International Business Centre(Moscow City)” is a building project in theRussian capital, the planning of which datesback to 1992. “Moscow City”, as it is knownfor short, is a completely new district in thecity that is being erected on the left bank ofthe Moskva River only 5 km away from theKremlin. The total cost of the project is esti-

mated at US $12 billion (approx. € 8.6 billi-on). On completion, numerous companiesand office buildings will be located here,among them the spectacular and also archi-tecturally demanding high-rise buildings.Completion of the entire complex is notexpected before 2012.

A PM service car in the Moscow traffic

us ively on Putzmeister concrete pumps – even

“Moscow City” is an entire complex ofmodern high-rise buildings

On the day of our visit to the constructionsite, no pumping operations were beingcarried out, and so there was time for aninterview with the M 42 machine operator

Gennadiy Loginov:PM: How long have you worked as a machineoperator with concrete pumps?GL: I started 10 years ago and I have operatedall of the PM pumps that Don-Stroy has.

PM: This is a M 42-5 from 2008. You say you have already pumped 80,000 m³ with it.What do you think about this machine?GL: It pumps just as reliably as all otherPutzmeister pumps. However, I especially

liked my previous machine with trunksystem. It however had a 4-arm boom. Incertain situations, there are more benefitsto the 5-arm machine with its greatermanoeuvrability.

PM: A great deal of information is shownon the graphic display of the control cabi-net. How do you use it?GL: I have not yet had any fault displays.This is certainly because we were instruct -ed well in how to use the machines and we keep to the main-tenance regulations. What I use is the oper-ating hours meter and the ECO switching.

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Mercury Tower: pumping height of 320 m

The 380 m high Mercury Tower is one of theskyscrapers in “Moscow City” that will laterattract everyone's attention. The 70-floorhigh-rise has been under construction since2005. As the lead construction company,Rasen Construction – a member of theTurkish Soyak-Holding – has been commis-sioned with the project. To deliver the, forthe most part, high-strength concrete to aheight of 320 m, Rasen Construction isusing three stationary Putzmeister BSA14000 HP D concrete pumps. The concreteis distributed in the floor and wall form-works using three MX 32-4 T stationarybooms that each sit on 20 m high tubularcolumns and climb upwards in the buildingshafts hydraulically. PM engineers haddeveloped solutions especially for theMercury Tower, so that the slewing radius ofthe boom ballast beams could be individual-ly set to the construction site requirements.

At Mercury Tower, three large BSA 14000 concrete pumps and three MX 32-4 statio-nary booms undertake concrete placement

The high-performance BSA 14000 SHP D pump won recognition during high-rise con-crete pumping at the Moscow Federation Tower

Model view of Mercury Tower

High-rise building for the Moscow City Council (308 m)

In the immediate vicinity of the MercuryTower, a new, 308 m high tower for theMoscow City Council (Tower of Moscow Go-vernment) is being constructed. Similarly, thebuilding contractor MonArch is completing

numerous concreting tasks using Putz-meister technology: a stationary BSA 2109 HEconcrete pump for delivering concrete, a hori-zontally slewable RV 10 rotary distributor,and two stationary MX 32-4 T booms.


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Construction of the Federation Toweris already very advanced

Federation Tower: high-strength concrete up to a height of 360 m

The building complex “Federazija” (Fede-ration Tower) is being erected on behalfof the investor Mirax Group and is alsoone of the technically and architecturallydemanding building construction pro-jects in “Moscow City”. The “Federazija”project consists in essence of two towerswith heights of 243 m and 360 m (440 m when the antenna is fitted later).Lead contractor for the construction ofthe eastern tower is the China StateConstruction Engineering Corporation;the contract for the western high-risebuilding was given to the Turkish build-ing contractor Ant Yapi.

Even during the winter months, extremestrength class C80/90 concrete will bepumped at the Federation Tower. Despitehigh-wearing concrete mixes, two Putz-meister high-performance BSA 14000SHP D concrete pumps have proventhemselves here over pumps made byother manufacturers (they were removedlong ago). Incidentally, the PM machinesare identical in design to the ultra-highpressure concrete pumps that were usedin the record-breaking high-rise pump-ing at Burj Dubai (606 m). While the top

floors are reserved as an observation deck,restaurants and a fitness club with swim-ming pool, there are 30 floors of office spa-ce underneath that are reserved for theRussian WTB-Bank – it is providing 50 % ofthe investment for the Federation Tower. Inaddition, a luxury hotel will take up a largenumber of the floors in the higher tower.The construction costs of the “Federazija”skyscraper are estimated at € 390 million.

For more information, see:www.soyak.com.trwww.rasen.com.trde.wikipedia.org/wiki/Moskau_Citywww.mirax.ru/content/33/Default.aspxen.wikipedia.org/wiki/Federation_Tower


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Service

PM: Mr. Drensek, you have many years ofexperience in service for construction machi-nery in various regions of the world. What is special about the service business inRussia?JD: The main thing to note is the vastdistances. In order to keep costs as low aspossible, we always try to solve problemsinitially by telephone. Our customers oftenhave their own local workshops and are ableto help themselves given the right instruc -tions.

PM: And what happens if this is not enough?JD: Then we always ask again, to prevent arepeat of a situation some time ago during aservice deployment in Vladivostok: At thattime, we had to fly 6,500 km because of adepressed emergency shut-down button ona M 36 truck-mounted concrete pump …Certainly an exception, but these things dohappen.

PM: And what is a normal case?JD: In addition to the headquarters inMoscow, we now also have two servicesupport bases in St. Petersburg andKrasnodar. If the site of use is less than800 km from one of these sites, we go the-re by car or with the night train. Distancesof over 800 km are really only possible byplane.Here in Moscow, we have almost all com-monly used parts in stock. If spare partsare needed for a job, these are sent to thecustomer first. Then, depending on the job,

extensive tools may be needed. It is notalways that you find the right equipmentat the construction sites or in the localworkshops. And then, coordinated withthe arrival of the parts, the service tech-nician starts to make his way. ForVladivostok, this can mean: departure inthe evening at 6 pm in Moscow, then eightand a half hour flight and eight hour timedifference. Arrival the next morning at10.30 am local time and direct departureto the construction site.

With 142 million inhabitants, the Rus-sian Federation is not only an economi-cally interesting market, but, with itswest-east expanse of over five and a halfthousand miles and an area of over 17million km², also very far-reaching. Thebiggest country in the world stretchesacross eleven time zones and, east ofthe Urals, has just a sparse road and railnetwork, and yet good flight connec-tions. We spoke to Jürgen Drensek, the 56year-old After Sales manager of PM RUS,to find out how the Putzmeister AfterSales department deals with these con-ditions, and how it organises support forcustomers and their machines throughto the far east.

The same applies in Russia: “PM expertise near you”

Service manager Jürgen Drensek andAndreas Milow, managing director of PM Rus

Training on the new BSA “far off the beaten track”

Arrival in the provinces: Thanks to good flight connections, the Russian PM servicetechnicians in this vast country can get (almost) anywhere very quickly

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St. Petersburg

Krasnodar

PM: … that’s certainly not easy for the servicetechnicians?JD: No, especially due to the physical strain.But we have a good team of willing people,who we have trained ourselves. Most ofthem were themselves truck-mounted con-crete pump drivers before. We then trained

them in PM technology and gradually intro-duced them to the more challenging servicework. Unfortunately, there is no apprentice-ship training in Russia like there is inGermany. Training here is very theory-ori-ented and the practical part has to be per-formed in the businesses.

PM: Does that not cost a lot?JD: Yes, of course, and above all, you need afew years to do it. But our customers expecta high-quality service package from Putz-meister and attest to it again and againthrough the trust they put in our service.

Service

The Russian Federation extends across eleven time zones and measures over five and a half thousand miles from east to west

View of the dispatch area of the Russian PM subsidiaryConstruction site preparation in themiddle of nowhere

Moscow

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Excavation

In three days and two nights, several truck-mounted concrete pumps concrete the huge bottom plate of Tower 185 at the same time

Pumping for all you’re worth ...The Frankfurt pumping service “The Pumas”pumped 15,056 m³ of concrete within 68hours in the second section of the hugebottom plate of the new Tower 185 inFrankfurt using four large boom truck-mounted concrete pumps.

To do this, a M 63-5, a machine with a 58 mboom and two M 52-5s were set up on twosides of the pit. In the course of the concret-ing, the end hose of one of the two M 52swas extended with pipelines, which wereconnected to an easy to use, hydraulicallycontrolled placing boom with a 20 m reach.The working range of this boom could beextended again, if necessary, through coup-ling with a mechanical rotary distributor RV 10. Three weeks before, the first sectionof the bottom plate was already cast with5,660 m³ concrete. The concrete was sup-plied by the Sehring and Waibel ready-mixconcrete plants.

New double-walled pipes (130 bar) with x-times extended service life

Both for the concrete pumping service andfor Putzmeister, Tower 185 is of interest foranother reason. For “The Pumas” also havethe order to concrete the basement floors,the base building and the two high-risetowers. And for the first time, double-walled,up to 130 bar pressure-resistant pipelineswith ZX couplings are going to be used forhigh-rise concrete pumping in the towers.Double-walled delivery lines have alreadybeen being used on PM truck-mounted con-crete pumps for a long time to extend theservice life (and thereby to reduce the con-version costs and downtimes), but only in a version limited to 85 bar pressure. For stationary use, the high-strength, double-walled delivery lines offer the advantage ofbeing able to withstand pressure up to 130bar for as long as it takes until the inner lay-er in the pipe is closed. This means there is

Over 20,000 m³ for the bottom plate

The planned 185 m tall high-rise buildingwith 50 stories is being built in Frankfurt’snew Europa quarter between the main trainstation, the trade fair site and the bankingquarter. Tower 185 essentially consists of amulti-storey underground car park, a hor-seshoe-shaped base building and two high-rise halves with aluminium-glass facade,which enclose a glass centre section. Theinvestor is Vivico Real Estate. It commis-sioned Hochtief Construction AG with com-pletion of the entire carcass. The pit wascreated in advance by Züblin SpezialtiefbauGmbH. The project is being financed by abank consortium with a credit volume ofEUR 254 million. Construction of the bottomplate started in March 2009 and the basebuilding is to be completed by autumn 2010.Completion of the construction work in the50th story is planned for the end of 2011.

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The Committee for European Construc-tion Equipment (CECE) has indicatedthat, at the start of 2010, the new EUDirective 765/2008 will enter into for-ce. Based on this ordinance, the cus-toms authorities at the EU external bor-ders, will inspect in detail if the construction equipment intended forimport actually meets the Europeansafety requirements, with effect fromthe start of the new year.

The reason is that for years, many con-struction machines – e.g. from Asia – havebeen sold in Europe, even though they donot meet the safety requirements in ac-cordance with EU standards. According to the German Association of Machine andPlant Engineering (Verband DeutscherMaschinen- und Anlagenbauer (VDMA)),one of the members of the CECE, this notonly distorts competition, but also leavespotential purchasers in the dark about theresulting significant risks. The GermanAssociation of Machine and Plant Engi-neering (VDMA) considers these risks toinclude an increased risk of accident,significant uncertainty in legal and liabili-ty questions after accidents, quality and

guarantee problems as well asdowntimes and fines.

But not only the illegal saleof machines is a thorn in

the eye for the CECE.Another aspect is the

labelling obligationof non CE-compli-

ant construc-

Background

no need for regular replacement of thehighly stressed delivery line pipes imme-diately next to the concrete pump at high-rise construction sites. For this first secti-on of the pipeline is subject to the greatestlevel of wear and the highest pressure.Wear experience with these delivery lineswill be reported in one of the next issues ofPM Post.

The speed of the work on this project isclear from a comparison of the two photos.The two pictures were taken at an intervalof less than six months.

For more information, see:www.vivico.dewww.diepumas.dewww.baunetz.de/Meldungen_Baubeginn_

fuer_Bueroturm_in_Frankfurt

Significant construction progress afterjust six months

For tight concreting deadlines, thesupply must flow efficiently

tion equipment, which are shown at tradefairs or open-house exhibitions, for exam-ple. The CECE is turning to dealers, con-struction companies, insurance companiesand banks. For although it is forbidden tosell machinery that does not conform tothe EU guidelines within the EuropeanUnion, these products may be exhibited attrade fairs provided they are labelledaccordingly. Obviously, these labels havebeen omitted, however. So, for example,random testing at INTERMAT, the biginternational construction machinery fairin Paris in April 2009, showed that themachines in question were not adequatelylabelled or had no labelling at all. In theinterest of the customer, CECE togetherwith the trade fair organisers will therefo-re ensure in future that the manufacturersmeet their obligation to label their pro-ducts.

This is why the CECE is speaking outagainst these illegal imports and supportsthe stricter import controls for construc-tion machinery.

By implementing qualification measures,the CECE wants to ensure that the EU aut-horities responsible for customs and mar-ket monitoring are able to check complian-ce with these standards.

For more information, see:www.vdma.orgwww.cece-eu.org

EU imposes stricter inspections on importedconstruction equipment

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The M 47-5 in practice – e.g. in Marseille harbourThe office tower and future headquar-ters of CMA CSM in the old harbour ofMarseille is being constructed nearthe quays, from which loads are takenfrom the containers of the internatio-nal logistics service provider. Aftercompletion of the building core, inwhich approx. 40,000 m³ concrete hasbeen placed, it is the turn of thesurrounding smaller structures.There, during our visit, a Putz -meister BSF 47-5.16 HLS wasbeing used. We took the oppor-tunity to talk with ChristopheAdelaide (CA), who has beenemployed in sales for the pump-ing service Maxi Pompage(Groupe ISP) for many years.

The M 47 “quintuplet” is really flexible again: Concrete placement from the outer end of the reinforcement to directly above themachine

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PM: What is special about it?CA: I compare the boom with 4-arm alterna-tives from the 40 m class. Above all, theextraordinary manoeuvrability of the fivearm boom is impressive. With this, you canoften compensate for a few metres morereach of a larger machine in the 50 m class.Simply because you can fold out closer to

the structure and the shorter individualarms allow for a more direct path to the siteof concrete placement. This is pure geome-try (see top graphic).

PM: And how does the machine operator copewith moving five boom arms?CA: Operation of the quintuplet is easy fromthe outset. We were relatively confident ofthis because we have already had manyyears of good experiences with the M 42-5.It helps that only two joysticks are requiredto move the five arms.

PM: A propos remote control. Since Bauma2007, a display for indication and operationof certain functions has been integrated. Howdo you use this?CA: The machine operator’s first focus is onthe machine, the boom and the man at theend hose. He only looks at the display inexceptional situations. So, for example, hecan read the speed of rotation if he no longerhears the engine running, check the fieldstrength if the radio link cuts off or can seehow much charge is still left in the battery.This provides safety. In addition, there areimportant on/off functions for the agitator,vibrator and others, which we use less often.

PM: The machine also has EBC, the computer-aided boom control.CA: Yes, although its use depends highly onthe individual method of operation of themachine operator. One colleague may notalways switch it on because he prefers tocontrol the boom directly. Others would takeadvantage of this opportunity, such as reliefstaff, who don’t work with the machineevery day.

PM: You mean, you don’t take advantage ofthe damping effect of the EBC?CA: But you would have to admit that theM 47-5 stands or pumps very quietly any-way. Although – the higher the pump out-put, the more important damping becomes.Then we can always switch over, so that theboom remains quiet even during a high place-ment and can be guided safely by the man atthe end hose.

PM: Mr. Adelaide, how long have you had theM 47-5 and how do you like it?CA: This large boom was added to our mobi-le concrete pump fleet, which consists of 28machines including three PUMI®s, in sum-mer 2008. The M 47 has pumped 10,000 m³to date. We are very happy with the machi-ne, above all with the 5-arm placing boom.

Christophe Adelaide (left) in a meeting with a service technician from PutzmeisterFrance and the machine operator of the M 47-5

The additional 5th arm and its hingeincrease the flexibility, number of appli-cations and net reach of a truck-mountedconcrete pump (top). Due to a lack ofmanoeuvrability, a 4-arm boom is muchmore difficult to slip into buildings. Itmay have to give up on attaining its netreach, depending on how great thedistance is.

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10:05

Growing within its niche –the Roline pump concept

Anyone driving onto the yard of Thomas Catherin Transport SARL in Montluel near Lyonwill look across to the fleet of around 15 closely parked lorries belonging to the smallhaulage and pumping service provider. The office and materials store of the family firmare housed in containers. Jean Marc Catherin, who built up the company on his owninitiative, tells us in his quiet, friendly manner why he changed from the PUMI® truck-mounted mixer pump two years ago to become the first in France to invest in a Rolineconcrete pump.

“I had four truck mixers, eight tippers and aPUMI®. This was similar to what many othershad to offer, which meant I didn't really standout from my competitors. That’s the back-ground to why I was interested right from thestart in the Roline machine concept. Withthis small, highly manoeuvrable machine, wecan undertake a wide variety of pumpingtasks economically, fast and sometimes evenmore simply than with a large truck-mountedconcrete pump. Add to this the fact that the

machine costs a lot less, both in terms of theinitial investment and the running costs (e.g.fuel consumption). And so I was sure I wasdoing the right thing when I ordered the firstmachine from Putzmeister in mid-2008...Of course, at first we had to familiarise ourcustomers with the Roline – that always takesa little time and effort. But then we began togain our first experiences of pumping con-crete with the system, in swimming pools,cellars, terraces behind houses and in inac-

No supports are required with theRoLine. Work can begin as soon as thereducer pipe is connected.

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10:12

10:18

10:25 10:40

Easy loading and unloading of the 3 m delivery hoses and couplings

The concrete work for the terrace is performed by the client with friends under theirown management. They also help with laying out the delivery pipes and hoses.

The RoLine concrete pump is designedin such a way that it can be convenient-ly filled from the truck mixer, and thedelivery line can be laid out

Filling the cement slurry to start pumping

The DN 75 delivery hoses are easy tohandle

Technical data RoLine

Pump R 60

Delivery rate (max./theor.) 58 m3/h

Delivery pressure 25 bar

Hopper volume 400 l

Overall length/width 6.4 m/2.0 m

Support not required

Technology

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11:10

12:15

11:15

11:40

lines can be easily laid over a length of up to3 m without any problem and can still bemoved by hand when concreting reinforce-ments, even when filled with concrete. Ofcourse they are not suitable for pumpingcoarse grain concrete, but we have success-fully used them for grain sizes of up to

20 mm. We cannot achieve really high pumpoutputs with the rotor, as the output is intheory limited to a max./theor. of 58 m³/h.But on smaller building sites, slower, conti-nuous pumping is often more appropriateand more efficient than going full speed ahe-ad and then having to hold back. Our working

As soon as the first square metres of the terrace have beenconcreted, the hoses – from back to front – are cut off andemptied over the reinforcement

After cleaning, the hoses are immediately stowed away

To clean the line, the rotor pump sucksthe wet sponge ball back

Finally, the hopper and pipes are cleaned. Dismantling and cleaning are completedafter just 40 minutes.

cessible narrow alleys. It all went so well thatwe already have a second machine. It is notour intention to compete with the large-scaleboom pumps; on the contrary, we limit ouractivities to concreting work where pumpingis easily carried out with a rotor or 75 mmdiameter delivery lines and hoses. These

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In order to be able to shut-off a deliveryline even in narrow spaces or to be ableto switch between different inlets andoutlets of a transfer tube in the high-pressure ZX delivery line system,Putzmeister has developed new com-ponents for use on construction sites.Some of the incentive to do thisstems from committed PM custo-mers.

methods are therefore economical for bothsides – for our customers and for our-selves.”

12:20 Finished!

The RoLine is the ideal concretepump for smaller construction companies and for applications in house and apartment construction.

• Almost no concrete residue in thesystem: – The customer receives the con-

crete volume he pays for– Quick and easy cleaning

• Jolt-free pumping process • Low hopper filling height • Light delivery line

– Safe operation up to 25 bar pumppressure

– Light and simple handling andfast readiness for operation

• Quiet pumping • Delivery rate is infinitely adjustable,

forwards and reverse • Even delivers difficult to pump

material • Quick and easy cleaning• Low wear:

The rotor hose is the only wear partof the pump and can be replacedvery quickly

• Easy maintenance • Putzmeister Service near you

There is not space on all construction sitesfor a large hydraulic gate valve or a separa-te hydraulic power pack. In light of this, thenew, manually operated hydraulic gate val-ve GVHM 2/2 130 was developed. The devi-ce is approved for a concrete pressure up to130 bar, so that it can even be integrated inconcrete lines for high and far placement.Due to its compact dimensions (set-up areaapprox. 26 x 26 cm, height 106 cm) thegate valve is, however, also suitable for useon narrow construction sites, such as intunnels.

The heart of the Putzmeister scissor pipeRS 0.76 ZX is an internally developed, axi-ally rotatable coupling for the high pressu-re Zentrifix delivery line system ZX 5.5”(approved up to 130 bar). Unlike the other-wise rigid ZX pipe connections, this con-struction allows, for the first time, a rota-ting – but at the same time completely tight– pipe connection in Zentrifix high pressu-re lines. This manoeuvrability is necessary,for example, if a concrete pump suppliestwo delivery lines alternately via one trans-fer tube. Or if you switch from one transfertube outlet to another during cleaning. Asthe line has to move to the side during thesliding process of the transfer tube and ZXcouplings to date do not allow for any angleof deviation, in the past the SK couplingdesigned for smaller loads had to be used.The new, mechanically much more stablescissor pipes and their couplings in ZXdesign now allow for much safer work withtransfer tubes.

Technology

The high-pressure scissor pipe for the ZX system

The new GVHM 2/2 shut-off valve, authorised up to 130 bar

New components forhigh-pressure resistantdelivery line system

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In Western China, at an altitude of 3,380m, two parallel railway tunnels 32.6 kmlong are currently being driven throughthe Guanjiao mountains. It is the longesttunnelling project that has ever beenundertaken in China. Putzmeister tech-nology was commissioned to secure theexcavation under extreme conditionsusing wet-shotcrete.

The spectacular structure is being construct-ed in a mountainous region that is difficultto access, and is set to replace the olderGuanjiao Tunnel (length 4 km) currently inuse and situated 300 m higher, but which isonly accessible via very windy access roads.Thanks to the perfectly straight routethrough the mountain situated at a loweraltitude, journey times will be shortenedconsiderably, and fuel savings will be signi-ficant as each train will have three diesellocomotives at the front. The sections of thenew Guanjiao Tunnel have beendesigned for train speeds of upto 160 km/h.

Shotcrete placement in 32kmlong high mountain tunnels

Transport of the Putzmeister shotcrete manipulator SPM 500 over a mountain pass at an altitude of nearly 3,500 m

The Chinese machine operator familiarises himself with the remote control of the SPM 500 PC

Technical data for the shotcrete system SPM 500 PC

Working height of the tele-scopingsprayer arm SA 14: 4.5–16 m

Delivery rate of the double piston shotcrete pump: 4–30 m³/h

Volume of the additive tank: 1.000 l

Delivery rate of the additive metering unit: 30–700 l/min

Compressor output: 9 m³/min.

Volume of the water tank: 195 l

Power cable: 50 m (100 m optional)

Operation of pump and boom: cable remote control

(radio remote control optional)

Drive output of the carrier truck, includ-ing with 4-wheel steering, all-wheeldrive, rotating driver’s cab 75 kW

Tunnelling

The construction site accommodation istightly packed

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New tunnel:Length: 32,605m

Old tunnel:Length: 4,010 m

The map shows the winding course ofthe old, 300 m high route section andthe position of the two new, significant-ly longer, single lane tunnel pipes(Picture courtesy of China Railway 16 Bureau Group)

Overview of the main Chinese rail routes (Fig. China Rail)

Chinese site personnel before the commissioning of the PM shotcrete machine

Concrete wet spraying machine withspecial spray arm kinematics

Initially, a Putzmeister SPM 500 PC concre-te wet spray manipulator will be used tosecure the excavation. In late 2009 a secondmachine of the same type will be put intooperation on the construction site. The all-wheel-drive and all-wheel-steered concretewet spray systems have a concrete pumpwhich delivers an extremely even supply ofshotcrete via hydraulic control. The shotcre-te is applied with a highly mobile spraynozzle in combination with special sprayarm kinematics. The hydraulic parallel gui-de of the front telescopic spray arm makes itpossible to automatically keep the completetelescopic spraying arm with nozzle in ahorizontal position – regardless of the angleof the first boom arm.

Tunnelling

Inhabitants of Xining in typical traditional costume

And it’s back towork again after

an oxygen shower

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Low temperatures and “thin air” take their toll

At temperatures as low as –36°C and atmos-pheric pressure reduced by one-third, the tun-nelling operations at an altitude of 3,380 mput a strain on workers and machine opera-

tors. Typical symptoms experienced by sitestaff include shortness of breath, exhaus-tion, headaches and nausea. In case of emer-gency, there is oxygen equipment availableat the construction site.

The compressor output of the spray gun atthis altitude is still at 100 % (the result of airvolume times pressure remains constant),and the low static pressure has an effect onthe suction in the shotcrete pump, at least intheory. However, at a maximum deliveryrate of 30 m³/h, this loss in output cannot bedetected in practice.

Of course, the low temperatures are a pro-blem (the annual average is below 0° C) –especially during the winter months. Thisalso results in the formation of ice in thetunnels. This means that the shotcreteaggregates are stored in such a way thatthey do not freeze, and that the additive andwater for the concrete batches and forcleaning purposes “free-flowing”…

For more information, see:www.crcc.cnwww.qh.xinhuanet.com

Faster to Tibet

The tunnels form part of the transportationroute (814 km) inaugurated in 1984 connect-ing Xining, capital of the Qinghai Province,and the city of Golmud situated furtherwest. From 2000 to 2005, the railway linewas extended by 1,142 km from Golmud toLhasa, capital of the Tibet AutonomousRegion (“Tibet Railway”). The China Railway16 Bureau Group is commissioned with build-ing over 17.3 km of tunnel – more than halfof the entire Guanjiao Tunnel Project. Thetwo single-track tunnels 40 m apart will bedriven up from all four entrances to createan excavated cross section of approx. 90 m².Progress will be made both with the use oftunnelling machines as well as with drillingand blasting techniques. As part of tunnel-ling operations – once excavated and withthe calotte strengthened with shotcrete –the walls and base are built moving a fewmeters at a time. The construction costs forthe new Guanjiao Tunnel come to 2.5 billionRBM (approx. € 250 million). The construc-tion time is estimated to be 53 months, andcompletion is planned for 2012.

The gradual conversion of the walls and base, which follow the

calotte tunnelling, is clear to see

For the S.O.B. piles, reaching down to14 m, augurs the height of houses arerequired

A BSA 1005 D delivers fine concrete tothe augured pile device

On the Caribbean island of Trinidad, threestationary BSA concrete pumps pump2,000 drilled piles for an enormous bot-tom plate, on which the modern La Brea720 MW gas turbine power plant is beingconstructed. The client for this $ 708million project (approx. € 480 million) isTrinidad Generation Unlimited (TGU).Completion of the power plant is notplanned before July 2011.

During the five-month foundation work, thethree Putzmeister BSA 1005 D were connect-ed to the top car of the drilling apparatus viaa flexible hose and pipework system. Thefoundation piles, which are up to 14 m deep,are produced as screw conveyor cast in pla-ce concrete (S.O.B.) piles. With this process,an endless screw conveyor with a liner issunk under constant rotation and almostwithout displacing any ground. As soon asthe desired depth is reached, the BSApumps pump the concrete down through theliner. At the same time, the drilling appara-tus pulls the drill upwards without rotating.A reinforcement basket is then driven intothe concrete-filled hole.At the La Brea construction site, the special-ists of Züblin Scandinavia A/S (Denmark)and Züblin Spezialtiefbau GmbH (Stuttgart)concrete the reinforced S.O.B. piles with adiameter of 60 cm. The main contractor of

the project is the Danish construction com-pany E. Phil & Sons.

BSA pumps concreteS.O.B. piles in Trinidad

Tunnelling / Excavation

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The Telebelt® TB 130 while placing concrete at the Braamhoek dam

The telescoping conveyor belt can be guided accurately over the reinforcement

Truck mixers load the Telebelt® feedconveyor. The insulation of the mixerdrum is also clear to see, as it protectsthe cooled concrete from the highambient temperatures

The Ingula pumped storage power stati-on will be the first hydroelectric powerstation to be built in South Africa foralmost 20 years to cater for future elec-tricity requirements. A mobile Telebelt®

telescopic conveyor capable of convey-ing concrete batches with aggregate 53 mm in diameter and a low cementcontent will be responsible for trans-porting the bulk concrete (RCC) to thelocation.

The construction site is located in KwaZulu-Natal, a province along the East coast ofSouth Africa that is home to almost 10 mil-lion inhabitants. The new pumped storagestation will consists of two reservoirs situ-ated 4.6 km from one another with a differ-ence of altitude of 470 m and connected bya hydropower tunnel. The access tunnelsand the turbine house will also be locatedunderground.

The construction of two dams will be requiredto create the water reservoirs. The 480 mlong, 49 m high Bedford dam will be con-structed from rock and encased in concreteand the lower Braamhoek dam will be 330 mlong, 39 m high and built from compressedbulk concrete containing coarse aggregate(roller-compacted concrete – RCC).

24 hours a day, 7 days a week

A Putzmeister Telebelt® TB 130 will be usedto transport and distribute bulk concretecontaining aggregate with a maximum dia-meter of 53 mm at the Braamhoek dam siteas well as concrete with other consistencies(a total of more than 100,000 m³). Themachine is the first mobile telescopic beltconveyor ever used in South Africa and isfrequently used around the clock, sevendays a week on the site. The concrete mixing plant is just 500 mfrom the dam construction site and has acapacity of 120 m³/h. The RCC contains a reduced cement share and must be inte-grated at a temperature of exactly 23°C. Thesummer months are much warmer, especi-ally during the day, and so the RCC processwater is cooled to 4°C in a separate coolingsystem prior to mixing.The owner of the Telebelt® is Concor – a com-pany that belongs to the Braamhoek Damconsortium. The consortium of the compa-nies Concor Roads and Earthworks, WBHORoads and Earthworks and Silver Rock hadpreviously won the contract against interna-tional competitors. The construction workbegan in November 2007 and is due forcompletion in 2012. When the Ingula powerstation is commissioned in 2013, it will

generate a turbine output of 1,332 MW,making it the largest pumped storage powerstation in South Africa.

Food for the Telebelt® – Bulk concrete for dam project

Power plant construction

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10 mm

Order now: Phone +49 (0) 173 3 09 26 63 · [email protected]

The New Generation Proline 67

Less Wear · Longer Service Life · Greater Economy

Simply lasts longer:

Proline 67

delivery line bend

Now with an almost 50 % thicker wear

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77 customer magazine by putzmeister concrete pumps gmbh

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