t
s
o
P
The magazine by Putzmeister Concrete Pumps GmbH
The world‘s biggest
stationary boom
on the Bosporus
M 6 placing concrete for
oil production platform in
Russia‘s Far East
Hoover Dam Bypass
Bridge – concreting at a
height of 4 m above
the Colorado River
9
Dancing Towers on
Hamburg‘s Reeperbahn
– three long-reach boom
pumps work in perfect
coordination
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Content
Content / worth knowing
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3
Title story
Hamburg: Dancing Towers
Three M 52 long-reach boom pumps used for the concreting
of the foundation slab of the new St. Pauli landmark
Exhibition
dates
4
October – December 2010
On site
Hoover Dam Bypass Bridge – the story of a “modern marvel”
Concreting at a height of 274 m above the Colorado River
Russia: M 62 placing concrete for oil production platform
„A single one-way ticket on the Trans-Siberian Railway
from Moscow to Vladivostok“ Turkey: The MXKD 50, the world‘s biggest stationary boom
Sensational find from ancient Constantinople – Port of
Theodosius discovered at the underground station in Yenikapı
04. – 08.10.2010
Elektra Mining, Johannesburg/SA
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27. – 30.10.2010
SAIE Bologna/Italy
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18
4
14
On the Reeperbahn
at six in the morning…
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22. – 25.11.2010
50 questions
How does Putzmeister manage to be so ubiquitous?
In each edition of PM Post we answer one of 50 interesting
questions from the last 50 years of Putzmeister 16
Launching of the first dredger in China equipped with
a Putzmeister KOS 25100 high-density solids pump
Putzmeister at construction sites in India
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23. – 26.11.2010
Bauma China, Shanghai/China
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By the
way…
Did you know that for many years
now, Putzmeister delivery cylinders have been hard chrome plat­
ed? As standard!
This is an important quality feature and extends the service life
substantially.
6
In brief
Putzmeister Academy – Seminar brochure for 2011
Big 5 Show, Dubai/UAE
M 62: 9,000 km
rail journey to the
Sea of Japan
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History lesson:
concreting at the
Port of Theodosius
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Dizzying heights:
Hoover Dam Bypass
Imprint:
Worth knowing
Exhibition dates / Interesting facts
Editor:
Putzmeister Concrete Pumps GmbH
Max-Eyth-Str. 10
72631 Aichtal · Germany
3
Photo credits:
Photo credits
Imprint
2
3
Unless indicated otherwise, all illustrations are copyright
Putzmeister Concrete Pumps GmbH.
18: www.datenland.de · 22: hoover_dam_nevada_luftaufnahme, Wikimedia Commons, licensed under CreativeCommons license by-sa-3.0, Florian Arnd · 26:
sea_of_okhotsk_map, Wikimedia Commons, licensed
under CreativeCommons license by-sa-3.0, Norman Einstein · 27: cape tihii, Wikimedia Commons, Vihljun · 28:
nivkh_men, Wikimedia Commons · 29: yuzhno sakhalin
museum (5), Wikimedia Commons, licensed under CreativeCommons license by-sa-3.0, Straitgate · 30: zametny
island, Wikimedia Commons, Vihljun · 35: istanbul rapid
transit map, Wikimedia Commons, licensed under CreativeCommons license by-sa-2.5, Maximilian Dörrbecker
PM 4307 GB
Editorial department:
Volker Wehner, Petra Montag
Putzmeister Concrete Pumps GmbH
Layout/DTP: Petra Montag
Putzmeister Concrete Pumps GmbH
Print:
Offizin Scheufele GmbH & Co. KG
Tränkestr. 17
70597 Stuttgart · Deutschland
PM 4307 GB
All rights and technical amendments reserved.
Although content is checked carefully, we
accept no liability for sites to which links
are given. The operators of external websites are solely liable for their content.
Some of the illustrations show special machine variants and snapshots which do not
always comply with the regulations of the
Industrial Employers’ Liability Insurance
Association.
© by Putzmeister Concrete Pumps GmbH
2010 · Printed in Germany (3.51009)
worth
know
ing
Title story
Title story
7
“Two new dancers on
Hamburg‘s Reeperbahn”
Following the plans of architects Bothe
Richter Teherani, the “Dancing Towers”
project was begun in September 009
quite close to the Port of Hamburg. On
the approx. 5,400 m² plot at no. 1 Reeperbahn, two pitched high-rise buildings
and a hotel complex are being built for
around € 150 million. The contractor is
Strabag Real Estate GmbH.
May 010 saw the second phase of concreting the ground level with a volume of
,650 m³ of concrete. PM has had a look
over the shoulders of those involved,
who own four Putzmeister long-reach
boom pumps (three in use plus one on
stand-by) of the BSF 5.0 H type provided by betonlift GmbH & Co. KG.
Pump Full support,
feeding by two truck
mixers at same time
Placing such a large amount of concrete
on a single day, even for the old hands of
construction firm Ed. Züblin AG, requires
some preparation in planning and consultation with the contractors. The concrete
supplier is Holcim Beton & Zuschlagstoffe
GmbH (Hamburg), the pumps are provided
by betonlift GmbH & Co. KG and Sociedade
de Construções, Lda (Lisbon) is responsible
for placing the concrete. On this day, 5th
May, work starts with the concreting concept for the bottom plate, which is subdivided into six concreting sections. The following marginal conditions apply:
• Max. plant capacity: 200 m³/h
(four mobile concrete plants, each
with 50 m³/h)
• Setting up three concrete pumps
• Having three construction crews at the
ready
The site management prepares the concreting plan for each concreting operation.
Concrete Technology
In the case of the second phase described
here, three different types of C30/37 concrete are used. For the lower part of the floor
and the diagonals, the maximum particle
size is reduced to 16 mm because of the high
density of the reinforcement (see the box).
This ensures that the steel is coated with
concrete on all sides. In the middle layers,
the maximum particle size is 32 mm, and for
the top layer, it is reduced to 16 mm again.
From the point of view of concrete technology, it is important to place the individual
layers in such a way that concreting is always carried out before the bulk concrete
of the previously placed layer begins to set.
This means that the bottom layer must still
be processible when the next layer is being
poured.
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The concreted section has a surface area
of 24.5 m x 42 m. For a concreting height
of 0.5 m, the concreting volume is approx.
330 m³ per layer with a maximum component thickness of 4.52 m (1.5 m in the
boundary areas) for the bottom layers. If
one assumes an average output of 150
m³/h, approx. two to three hours will
be required for concreting each layer.
For the upper area, up to 550 m³ per
layer and three to four hours workability time are set aside. This means that
the workability time for the concrete
supplied for the lower layers must be
slowed to four hours, and five hours
for the upper layers – even once any
change in location of the pumps has
been taken into account.
Mixture breakdown for the bottom plate bulk concrete
bottom area
middle area
upper area
Consistency
F5 (58 ± 2 cm)
F5 (55 ± 2 cm)
F4 (53 ± 2 cm)
Workability time
up to 6 hrs
up to 10 hrs
up to 2 hrs
Fresh concrete properties
Pump OSS (One side support), 180° forwards
working area
Hardened concrete properties
Property class
C 30/37
C 30/37
C 30/37
Exposure classes
XC2, XC3
XC2, XC3
XC3, XD1
betonlift
Service truck
with „caboose“
Stand-by pump
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Pump OSS (One side support), 180° forwards
working area
1
4
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Title story
Title story
p For some in St. Pauli, this early hour means hometime, but for the workers on the construction site, the day is only just starting:
At half past 5 sharp, the first truck mixers arrive.
p Keeping an overview: Three booms, moving construction site cranes, constant changing of truck mixers – the construction site
requires the utmost attentiveness from the machine operators.
Placing concrete - from a practical
viewpoint
Franz Syrowatka from betonlift Hamburg
adds: “To us it was clear that we would be
using our Putzmeister 52 m booms; three in
action and one as a stand-by pump with one
machine operator to relieve colleagues dur­
ing the day. The important thing for pumps
1 and 3 was the one side support, and that
we have a working area of 180°. This was
the only way that we were able to reach all
corners of the area to be concreted. With
pump 2, we had somewhat more space. We
Laughing when asked what the greatest
challenge for placing concrete is, project
lead Silke Pförtner from Ed. Züblin AG answers: “When you see the depth of the pit, the
type of pit lining and the size of the area set
aside for the construction site equipment,
it soon becomes clear: There isn‘t actually
any space for large machines. In addition,
the hours allowed for concreting are clearly delimited because we have to respect our
neighbours, and therefore we need as many
pumps as possible. So we have teamed up
with betonlift to develop a very target-oriented, fair, good and safe solution. Because
when placing large amounts of concrete as
you see today, we really can‘t leave anything
to chance. So, for example, we worked with
betonlift to determine first of all the locations of the three pumps (see fig. 7 and 9),
restricted as we were by a very small set-up
area, the maximum load on the supporting
ground at the edge of the pit, and the access
options for the truck mixers.”
q Don‘t push: Each truck mixer in the
convoy is guided to the appropriate
pump by the signaller.
Pump 2 (far left) has a somewhat larger
set-up area and can be fed by two truck
mixers at the same time.
11
were able to provide full support there, and
were able to load using two truck mixers at
the same time. This enabled the P2 to reach
a somewhat higher effective pumping rate
per hour.”
An average pouring rate of 180 m³/h was
assumed for the three pumps combined. At
2,650 m³, this meant a pumping duration of
approx. 14 hours. Therefore, concreting was
set to begin early, at 6:00 am. To save some
time, the four concrete pumps were moved
into place the evening before, which meant
that all that remained to be done was to
set up the machine supports and move the
boom into its working position anytime from
5:00 am onwards. Around 5:30 am, the first
Holcim truck mixer arrived from the plant
approx. 15 km away, and shortly after 6:00
am, the first concrete started to flow. In total,
there were 45 truck mixers constantly driv­
ing to and fro, transporting the concrete to
the “Dancing Towers”.
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t A fence reduces the street width
by half: On one side, traffic can pass
by unhindered, and on the other, the
truck mixers control the M 52, which
is supported on one side. The one side
support (OSS) for pumps 1 and 3 was
crucial for their use in the tight space
available.
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Title story
Title story
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Concreting within tight reinforcement
Because in this area for concreting alone the
reinforcement consisted of 776 t of steel,
the meshing structure was so dense that
specially marked concreting openings (d
= 0.2 m) were planned in a 10 m x 10 m
grid for inserting the end hoses (see fig. 14).
This allowed the boom to be mainly moved
from point to point at lengthy intervals. However, the machine operators could not take
their eyes off the ball for a moment, because
the interruptions caused by the frequent
changes of truck mixers had to be agreed
with the concreting team. In addition, the
machine operators also had to keep the other
placing booms and cranes within view, as
they were moving at the same time. Not an
easy job, when you consider that on this particular day, work started around 4:00 am in
the depot at betonlift, and that the construction site had special permission to work until 11:00 pm, to be on the safe side.
15
for the next round of work. And because every construction site worker is welcome, we
have a good reputation. It helps us particularly when, being far from home, there are
problems from time to time. For example, a
locksmith can be on hand quickly if necessary, or people who can help to clear out a pipe
fast if there is a blockage. In my opinion, we
get back many times what we‘ve put in.”
Guten Appetit, or is that Bom Apetite?
The same must surely apply to the men
from Zucotec, mostly Portuguese, who were
responsible for placing the concrete inside
the reinforcements, spreading it, venting
and smoothing it. As a spicy aroma begins to
waft across the pit around the middle of the
day, we cram into one of the site containers
in search of the chef, who proudly presents
two trays of fried chicken for his fellow Portuguese countrymen (see fig. 16).
At around 9:30 pm, the last Holcim truck mixer has been emptied, and even all 2,650 m³
of the top layer of floor concrete, with its target consistency of F5, has been successfully
placed. All that remained was smoothing,
tidying up and cleaning. And when PM asked again the following day how the collaboration went, project lead Silke Pförtner and
Franz Syrowatka from betonlift agreed: “The
work was hard but was shared equally and
ran smoothly.” ■
© www.datenland.de
‚ The Dancing Towers
of St. Pauli
Soon to reach up to 85 m in height, the
pitched “Dancing Towers” have already
become the new symbol of the St. Pauli
district. Combined with the inclinations
in the buildings‘ structure, nocturnal illumination is meant to make it look as
though the towers are dancing.
Top planning combined with a good
working atmosphere produces a high
level of efficiency
In addition to offices and a hotel, the
“Mojo Club” will return to its former
address of No.1 Reeperbahn. From 1993
it was an internationally renowned attention in the nightlife scene of St. Pauli.
16
The working atmosphere and level of cooperation on the construction site were remarkably good. Contributing to this are very
good organisation of processes and certainly
the mobile combination of workshop and
“caboose”, which Jürgen Bitsch from betonlift Hamburg sends to the construction site
to supply the team for such large-scale operations (see fig. 17). His explanation sounds
quite simple:
“When you require a lot from your team, you
also have to provide some relief for them.
And when you experience what the machine
operators and many others have to put up
with on the construction site, in cold and wet
weather, then it quickly becomes clear that
they really value a cup of coffee or a bowl of
hot stew. It motivates them and refuels them
The towers are due for completion in
summer 2012.
Webcam at the No.1 Reeperbahn
construction site:
‚ http://baustelle.strabag.at
(various construction sites can be
viewed)
17
Spectacular construction projects by
architects Bothe Richter Teherani:
‚ www.brt.de
Always worth a visit –
the Hanseatic city of Hamburg
‚ www.hamburg.de
p Because of the extremely dense
network of reinforcements, the workers
can only feed in the end hose at the
specially marked points.
t An army marches on its stomach:
A hearty stew with sausages from the
“betonlift canteen” and Portuguese
fried chicken “à la Zucotec” provide new
strength.
t Working in the supporting ground:
Zucotec workers are inside the reinforcements while the bottom layer is
being concreted.
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On site
On site
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The making of a
“Modern Marvel”
[Putzmeister America, October 2009]
The Mike O‘Callaghan-Pat Tillman Memorial Bridge – better known as the Hoover
Dam Bypass Bridge – is one of the most
ambitious construction projects in the
USA. With a span of 323 m between the
twin concrete arches, once complete, it
will be the longest in North America and
the fifth longest concrete arch bridge in
the world. Its apex reaches a height of
274 m over the Colorado River.
Stationary concrete pumps and placing
booms from Putzmeister mastered the
high demands of concrete pumping in
this Colorado River bridge construction
project.
As was done 76 years ago, the Hoover Dam
is again making its mark in history books.
Crews are conquering an engineering feat of
constructing the most technically challeng­
ing bridge ever to be built in North America, the Colorado River Bridge. To help place
concrete for this one-of-a-kind project, two
Putzmeister placing booms and BSA trailer
pumps are taking on the obstacles presented
by the Hoover Dam surroundings.
The bridge is part of the Hoover Dam Bypass
project, will hover around 274 m above the
Colorado River and run parallel to the dam.
The bridge, with two lanes in each direction,
is being built in an effort to alleviate traffic
on U.S. Highway 93, which currently crosses
the Hoover Dam to pass over the Colorado
River.
Because the highway is the major commercial corridor between Arizona, Nevada and
Utah as well as on the North American Free
Trade Agreement (NAFTA) route between
approach, helping us from the beginning of
the project.
The placing system they chose to maximize
their concrete placement for the arch was
MX 32-4 Multi and MX 36-4 Multi placing
booms and BSA 2107 HP-E and BSA 2109
H-E trailer pumps.”
Mexico and Canada, the traffic congestion
(an average of 14,000 vehicles a day) caused
by the existing highway across the dam,
imposes a serious economic burden to the
country.
In addition, the traffic volumes, combined
with the sharp curves of the highway near
the Hoover Dam, create a potentially dangerous situation for Hoover Dam visitors
and dam facilities. Once the Colorado River
Bridge is complete, no through or truck traffic will be allowed on the existing roadway;
only Hoover Dam visitors will be permitted.
Overcoming the extreme
To date, Obayashi/PSM JV has pumped and
placed about 10,000 cubic yards (7,646 m3)
of concrete for the Colorado River Bridge.
Jeff St. John, project manager of Obayashi/
PSM JV, says the pump manufacturer helped
their team determine how and where to
mount the placing booms and position the
trailer pumps for all portions of the project.
“For construction of the twin arches, we positioned one trailer pump near the base of
the Nevada arches and one on top of the arch
footing in Arizona,” comments St. John. “A
placing boom was also positioned on each
the Nevada and Arizona side of the twin
arches.”
The separate placing booms and their pedes­
tals were flown via crane to each of the twin
arches for mounting on their specially-de­
signed platforms.
As a result of the blazing heat, and to
prevent traffic problems, most of the
concreting was carried out at night.
20
Choosing the right system
Obayashi/PSM JV, a joint venture of Obayashi Corporation and PSM Construction USA,
Inc., the general contractor, began construction on the 579 m long open spandrel deck
arch bridge in early 2005.
Obayashi/PSM JV had its work cut out for
them; the project included the pre-casting
and erection of pier columns up to 91 m tall;
construction of the twin, cast-in-place segmental concrete arch spans; and the installation of temporary twin cable stays that have
a 762 m span and are 101 m tall to support
the arches during construction.
“We called Putzmeister right away to discuss
the project and what our possible concrete
placing solutions for this complicated project would be,” says Wes Pollnow, construction manager of Obayashi/PSM JV. “We
needed to know which solution would make
the most sense and which would be most efficient; they have a true complete systems
Planned amounts of concrete and steel for bridge construction
69 N/mm2 concrete in the arches
6,499 m3
41 N/mm2 concrete in the pier columns and caps
6,395 m3
31 N/mm concrete in the bridge deck
4,193 m3
28 N/mm2 concrete in the footings and abutments
5,106 m3
21 N/mm concrete for column infill
1,575 m3
2
2
Reinforcing steel
3,765 t
Structural steel
3,084 t
Post-tensioning steel (permanent)
384 t
Post-tensioning steel (temporary)
680 t
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On site
On site
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In order to avoid the intense heat and avoid
traffic congestion, most of the concrete placements occurred at night. Once the placing
booms and trailer pumps were in position,
they were ready to step up to overcome the
38 °C weather, while pumping and placing
the notorious, harsh Nevada concrete mix
up 85 m and out 162 m.
“All of the concrete mixes used for the arch
were advanced concrete mix designs using
harsh aggregates,” says St. John. “Liquid
nitrogen has been used extensively for precooling of the concrete in order to reduce the
temperature the concrete reaches during curing.”
For the arches, a high-strength 69 N/mm2
concrete mix was used, and for the columns
and pier caps a high-strength 41 N/mm2 mix
was used.
Early in the project the concrete mixes were
provided by Casino Ready Mix and Silver
State Materials (now a part of the CalPortland Company), however in late 2007 Obayashi/PSM JV began operating their own
concrete batch plant for the arch and deck
concrete, and will continue to make their
own until the project is complete.
“Even with the combination of the heat and
the harsh mix, the trailer pumps were able to
easily maintain a continuous concrete flow,
at a timely pace, up to the placing booms
so it would not clog the pipe system in the
extreme conditions,” comments Pollnow. “In
addition, the S-valves on the pumps had no
problem gulping down the tough concrete
mixes.”
The trailer pumps are able to provide a
smooth, more controllable output of concrete
because of each pump’s free flow hydraulic
technology. Both pumps have a fully adjustable volume control to allow very slow pumping while retaining full concrete pressure.
The pumps have been outputting around
12 m3/h due to the job site’s extraordinary
environment conditions.
“The pumps really provided that extra
muscle we needed to push the concrete up
and out to its final destination, and in fact,
both trailer pumps have the capability to
pump concrete up to 244 m high. Also, the
capabilities of the placing booms helped immensely to reach the exact point of concrete
placement for each segment of the twin
arches. Again, because of the unconventional setup, we really needed dependable
booms, and they did not disappoint.”
t The airy workplace for the
placing booms
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Quinn Concrete Pumping, Las Vegas
Quinn Concrete Pumping, Inc. (Quinn) of Las
Vegas has also lent its services to the Colorado River Bridge project. Quinn has supplied
both pump operators and has provided their
own Putzmeister equipment.
“Quinn was on site quite early on in the
project for the footing and arch foundation
concrete,” notes St. John. “They are a great
team to work with, very dependable. We expect they’ll also be involved with placing the
deck concrete as well.”
Most notably, Quinn’s M 42 and M 58 truckmounted concrete boom pumps were on site
back in 2005 to pump and place concrete for
the Colorado River Bridge’s pier. The pier
provides foundation for the vertical columns
needed to support the arch of the bridge.
“The 58-meter boom pump was positioned
atop a cliff’s edge on site, and used its full
boom length to place concrete into the hopper of the M 42 which was situated in a gorge
below on another cliff,” says Pollnow. “The
M 42 then stretched its boom to pump and
place the concrete to its final destination.
The equipment setup and performance was
truly remarkable.”
As of October 2009, Quinn has placed about
3,823 m3 for the Colorado River Bridge project and about 80 percent of the bridge was
complete. The remaining work on the project includes erecting the precast spandrel
columns, installing tub girders, casting the
pier caps, the deck, then the barrier walls
and approach slabs.
Concrete placement is anticipated to be complete during summer 2010, with the bridge
opening for public use in November 2010. ■
p Each state had a stationary concrete
pump: one in Nevada and one on the
Arizona-side of the Colorado River.
22
Hoover Dam Bypass Bridge
Boulder Dam? Hoover Dam?
Originally started as the “Boulder Dam”
project, the dam was renamed to “Hoover Dam” at the beginning of the official
construction phase. At this time, Herbert
C. Hoover was standing for re-election as
president. Despite linking his name to this
construction project, which created many
thousands of jobs during the Great Depression, Hoover lost the election. In 1933, the
dam was again called Boulder Dam, but 14
years later, and ever since, the dam was
again called Hoover Dam.
Owner/Developer:
Federal Highway Administration/Washington, D.C. · Arizona Department of Transportation/Phoenix, Arizona · Nevada Department of Transportation/Carson City,
Nevada · U.S. Bureau of Reclamation · National Park Service · Western Area Power
Administration/Lakewood, Colorado
Design Team:
T.Y. Lin International/San Francisco, California · HDR Engineering · Sverdrup Civil,
Inc.
General Contractor, Concrete pump
supplier and concrete ready mix
supplier:
Obayashi/PSM JV, a Joint Venture of Obayashi Corporation and PSM Construction
USA, Inc./Boulder City, Nevada
Concrete pump sub-contractor:
Quinn Concrete Pumping, Inc./Las Vegas,
Nevada
Additional concrete ready mix
suppliers:
Casino Ready Mix/Las Vegas, Nevada · Silver State Materials/Las Vegas, Nevada
Equipment:
Obayashi/PSM JV: Stationary concrete
pumps BSA 2107 HP-E and BSA 2109 HE, placing booms MX 32-4 Multi and MX
36-4 Multi
Quinn Concrete Pumping: M 42 and M 52
truck-mounted concrete pumps
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‚ The Hoover Dam –
interesting and intriguing
Concrete on a huge scale
The Hoover Dam was constructed as an
arch gravity dam between 1931 and 1935
with a height of 221 m and a crest width
of about 14 m. The base width is 201 m.
Approximately 2.6 million m3 of concrete
was used in the construction of the dam.
The dam was not cast as a single piece but,
instead, was created from a large number
of individual trapezoidal concrete blocks
that were 1.5 m in height. Each block contained a series of pipelines through which
the cool water circulated. As a result, the
heat that is produced as the concrete sets
is conducted away at a considerably quicker rate. Without this measure, the concrete
would have taken approximately 105 years
to cool!
The metropolis of gambling grew as
the dam grew
The town of Boulder City was built specifically to house workers involved in the
construction along with their families.
However, gambling and alcohol were prohibited in Boulder City. It was therefore only
logical for workers to use their free time
to make the pilgrimage to the small desert
settlement of Las Vegas, 50 km away. Bars
and Casinos started to emerge in no time.
Las Vegas without electricity? Unimaginable! However, a curious fact is that at the
time when the electricity purchasing rights
from the hydroelectric power station at the
Hoover Dam were being negotiated, the
desert city‘s mayor at that time rejected
any purchase, saying “Las Vegas will never have more than 5,000 inhabitants”. As
a result, Las Vegas currently only receives
about three percent of its annual electricity demand from the nearby Hoover Dam
hydroelectric station.
1
On site
On site
24
26
In March of this year, a brand new M 6-6
travelled over 9,000 kilometres on the
Trans-Siberian Railway from Moscow to
Vladivostok.
The customer – Stroitel’nyi Aljans – is currently using this long-reach boom pump 180
km away in Nakhodka, a port city on the Pacific coast of the Russian Far East. Together
with its older brother – an M 44-5 that was
manufactured in 1996 and that Stroitel’nyi
Aljans acquired second-hand from Japan in
2004 – the M 62-6 is concreting the base of
a large oil platform.
t Well lashed – in Moscow, the M 6-6
commences its long journey to the far
east with the Trans-Siberian Railway.
Russia – vast country,
long journey: 9,000 km
by train to the site
This GBS – Gravity Based Structure – consists of a concrete slab that has an area of
approximately 100 x 127 m and is 13 m
thick and on which four shaft towers – 25 m
in diameter and 41 m high – will be erected.
The complete structure will be concreted on
land and will then be towed by ship to an oil
field just off the coast of the island of Sakhalin and, from there, it will be lowered to the
seabed at a depth of 35 m. The client is the
Norwegian company Aker Solutions.
In total, the two Putzmeister pumps will
place 55,000 cubic metres of concrete before
the end of 2011. ■
‚ www.sakhalin.ru/engl/
Information about Russia‘s largest
island (engl.)
‚ www.sakhalin1.com/en/
An area just off the coast of the island of
Sakhalin in the far north-east of Russia
is said to contain the largest untapped reserves of oil and gas in the world. In oil
alone, it is estimated that there are 13 billion barrels in this area.
The Arkutun-Dagi field – part of the
Sakhalin-1 project and the future site of
use for the GBS that is currently under
construction in Nakhodka – is located
only a few kilometres off the coast of Sakhalin. The US oil company Exxon-Mobil is
investing about 12 billion US dollars in
the development of the three oil and gas
fields (in total), amounting to the largest
direct investment by a foreign company
in Russia to date. Approximately 13,000
jobs have been created (directly and indi-
China
Information about the oil and gas
development of Sakhalin-1 (engl.)
Written and researched by the locals,
“Way to Russia” is a very popular independent guide to Russia online (engl.)
rectly) from the development of these raw
material reserves and the tax revenue for
the region has doubled. The island has the
highest proportion of foreign nationals of
all the Russian regions and an above-average share of English-speaking Russians.
Russia
Kamchatka
Peninsula
Sea of Okhotsk
Arkutun-Dagi
oil and natural
gas field
Sakhalin
‚ www.waytorussia.net
q In the port city of Nakhodka, the
M 6-6 and M 44-5 together are pumping a total of 55,000 cubic metres of
concrete for an oil platform.
Arctic Ocean
Vast oil and gas reserves
in the Russian Far East
r
Ku
Nakhodka
North Korea
Hokkaido
il
ds
an
Isl
Pazific Ocean
25
Sakhalin – affectionately named “the wild
dishevelled animal” in the language of the
indigenous people – is 948 km long and between 27 and 160 km wide and is situated to
the north of the Japanese island of Hokkaido
in the Pacific.
With 650,000 inhabitants, this is Russia‘s
biggest island and only 3,150 of these inhabitants belong to the indigenous groups of the
Nivkh, Nani, Orok and Evenki. They live selfsufficiently, as fishermen, as herdsmen or by
collecting wild plants.
Ceded to the Russian Empire in 1875, the
south of the island was ruled by Japan from
1905 until 1945. The few remaining indige-
nous people were forced to leave their homeland and travel in the direction of Hokkaido.
Since the 19th century, the island had been
used as a penal colony for Russian prisoners.
The inhabitants who live there today – except for those who immigrated as a result of
the raw materials boom – are descendants of
the former forced labourers.
With approximately 175,000 inhabitants,
the island‘s capital Yuzhno-Sakhalinsk is
the largest city on the island. However, most
of Sakhalin is made up of largely untouched
boreal forest or mountains and has a population density of 6.2 inhabitants per square
metre – half as much as in Norway.
Sakhalin – Сахалин
27
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Sakhalin is currently trying to find a balance
between becoming an ambitious economic
region and nature resort, between tourism
ambitions and the threat of damage to the
environment.
q (from left to right) Cape Tihii (“Quiet
Cape”) in the Sea of Okhotsk · Nivkh
hunters in their traditional dress · The
state museum in Yuzhno-Sakhalinsk
provides evidence of the former Japanese reign · The island of Zametny in the
Tihaya Bay
29
30
15
50 questions
The company · Question 9
How does Putzmeister manage
to be such a global presence?
Putzmeister promises “Competence
near you”. This is a bold claim for a company whose customers are dispersed
all around the world. It‘s a claim that
Putzmeister lives up to with modern
communications technologies, a dense
service network and the best possible
relationships with distribution partners
in every corner of the globe.
Since Putzmeister sold its first machine
abroad, the company has gradually opened
up one world market after another. Peter
Dörr was an instrumental part of this process. Since 1984, the 67-year-old has travelled the Near East and the countries of Asia
in order to sell machines made in Aichtal.
And his record is a successful one.
“In Vietnam, we started out as a tiny operation. We sold our first machine at an agricultural trade fair,” recalls Dörr. Hoang Minh
Hung turned out to be a born entrepreneur.
In 2001, he employed a technician for the
after-sales service and set up a small spare
parts warehouse in Hanoi. His company,
Minh Hoang & Co, now has 20 employees
and two offices in Hanoi and Ho Chi Minh
City.
Many Putzmeister distribution partners
all over the world can tell a similar story.
“These partners have grown with us. This
results in very close and resilient relationships,” says Dörr.
A close network of specialists
50 questions
9
32
subsidiaries and dealers is now present in
more than 100 countries. The headquarters
in Aichtal and the regional subsidiaries offer support in the form of service engineers,
training specialists and a team of service
technicians.
Together, they ensure that Putzmeister customers always receive competent advice, are
efficiently supplied with spare parts and can
depend on a speedy and reliable after-sales
service, no matter where in the world their
machines are put to use.
In many cases, Putzmeister service technicians do not even need to visit the site.
Thanks to modern telecommunication technologies, they can often diagnose and rectify
fault causes easily from their PC.
Our Putzmeister Partner in Vietnam:
This is how Putzmeister continues to guarantee “Competence near you” worldwide. ■
Minh Hoang & Co.
4 Pham Huy Thong · Hanoi
Asked about the secret of his success, Dörr
doesn‘t take long to find a response: “You
have to be interested in people. Of course,
you also need a good product. But interpersonal relationships are crucial. If you want
to be successful in a foreign country, you
need to have distribution partners there who
are prepared to nurture these relationships
and will be there for their customers 100
percent.”
Putzmeister has mostly been blessed with a
lucky touch when it comes to the selection
of distribution partners. The worldwide service and distribution network of Putzmeister
Hoang Minh Hung is one of these distribution partners. The 47-year-old represents
Putzmeister in Vietnam. “He‘ll bend over
backwards for us and his customers whenever it‘s necessary,” says Peter Dörr. When
Dörr first met Hung back in 1993, Hung had
no capital. What he did have, however, were
intimate and trusted ties with many potential customers, and he was convinced by
Putzmeister products. Dörr gave Hung a moped. They would dash through Hanoi and Ho
Chi Minh City, sometimes even side by side,
to visit customers and deliver spare parts.
q Hoang Minh Hung (nd from left) with his family and the partners of Putzmeister:
Friedemann Bornträger (rd from left), Peter Dörr (nd from right) and Johnson Ong
(far right)
Mr. Hoang Minh Hung
Tel: +84-4-1950
Fax: +84-4-195
E-mail: mhc-hanoi@hn.vnn.vn
p Since the 1990s, Putzmeister concrete pumps have even serviced Vietnamese
construction sites.
31
q A Putzmeister stationary concrete pump
on the way through the streets of Hanoi.
33
q In Vietnam, the motto is “even the
smallest moped has room”.
34
?
We‘ve picked 50 questions from
over 50 years of Putzmeister and
given the answers some serious
thought.
From now on, we‘ll be featuring one
question in each new edition.
16
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On site
On site
MXKD 50 and BSA 110 HP D
concreting the underground
rail station in Yenikapı / Istanbul
In February 010, the time had finally come: an MXKD 50 on a 15 m lattice
tower and a BSA 110 HP D stationary
concrete pump began concreting the
Yenikapı railway station.
35
I STA N B U L
36
This is the only station of the new Marmaray
tunnel line being constructed using the cutand-cover method. Its bottom surface mea-
sures approximately 300 m long and 35 m
wide. For the concreting of the foundations,
it was divided into a total of 29 sections.
Each section – approximately 10 x 35 m
and 2 m thick – is being concreted monolithically in multiple layers of 40 cm. Each
layer contains some 120 m3 concrete, which
produces an average of 650 m3 for each of
the 29 sections.
.
Technical data BSA 110 HP D
Output up to
Concrete pressure up to
Engine
Delivery cylinder Ø
Stroke
102 m3/h
220 bar
330 kW Diesel
200 mm
2100 mm
rus
o
osp
B
38
Historic
city center
aray on
m
r
a
ti
M
l sec
e
n
n
tu
Yenikapı
t Pipeline fastenings
in the horizontal section
ZX 15/5”-10 bar
Sea of Marmara
MXKD 50 at the centre
of an archaeological sensation
The construction of a new, state-of-the-art
transport interchange is supposed to be underway here, in Yenikapı, on the European
side of the Bosporus: a major rail transit
station to serve the 15-million metropolis of
Istanbul. When the ground was broken back
in 2004, nobody thought that the project
would be set back by the discovery of an important transport hub from Constantinople‘s
past.
What was a great moment for archaeology
(Yenikapı is the largest urban excavation
and one of the most significant finds in Turkey) has caused developers to suffer serious
time delays and, of course, to incur enormous costs.
Yenikapı is situated on the southern shore
of Istanbul‘s old town on the Sea of Marmara. With the future construction of its major
rail transit station serving the “Marmaray”
undersea tunnel under the Bosporus strait,
Yenikapı is intended to offer passengers a
means of changing from overground to un-
q While some go to work with heavy machinery, others require rather more delicate tools, such as a trowels and brushes.
In the foreground are unearthed fragments of the ancient harbour wall.
derground trains. Originally, a new regional train station had also been planned in
order to connect suburban commuter traffic to the East-West network. However, this
aspect of the project had to be changed:
such is the importance of the ancient port,
the local heritage trust decided that it
would have to remain exactly where it is.
q Discovery site of one
of the wooden ships
39
37
First of all, the excavation of the pit for the
new, 21st century subway station on the
Marmaray tunnel line unearthed a series of
ancient walls. As it turned out, these belonged to an important Byzantine trading port,
a transport hub of the “global world” dating
back to around 400 AD. The “Port of Theodosius” – named after the last ruler of the
Eastern Roman and Byzantine Empire – contained the remains of, to date, more than 30
ships, the largest single discovery of ship
relics anywhere in the world. Among them
were four Byzantine dromons, the oldest
warships ever to have been discovered. They
must have been sunk around 1000 AD.
18
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On site
In brief
40
41
43
Putzmeister Academy
Seminars 010/011
p Hydraulic gate valve GVHM / converted for installation in a vertical line
p The hopper of the stationary concrete pump is cleaned under high pressure, and
cleansing water is then pumped through forwards.
Five set-up sites are planned for the MXKD
50, which will all enable it to reach each
point of the foundation area. This means
that it will have to be relocated four times.
The boom anchor set is located in the centre
of the reinforcement of one of the foundation sections. As the boom foundation needs
to have a certain amount of strength before
subsequent anchoring can take place, a
defined workflow has been planned for the
concreting of the individual positions. When
each section gets its turn is absolutely crucial to avoiding unnecessary waiting times
in the re-siting of the lattice tower.
The concrete mix is particularly challenging.
Despite a strength class of “only” C40, the
high additives content makes it awkward to
pump. These additives are necessary because
the concrete must be able to withstand a
high groundwater pressure.
Our seminar brochures for
2010/2011 (German language),
containing dates and information
about courses and training, will
be sent out by post in October.
Find out about the current dates for the
next “season”, sign up in good time and
reserve your customised company seminar.
In our seminar brochures for
different target groups, we demonstrate what is important:
preventing accidents, increasing efficiency and lowering
costs.
If you have not yet received your copy,
then please contact us by e-mail:
akademie@pmw.de
In total, the concreting time of the subway
station (foundations, walls, shafts, etc.) is estimated to take 15 months to complete. ■
q The huge stationary boom at the
start of foundation concreting.
In the background are the tunnels of
the future underground line.
42
Launch of the first
dredging boat in China
with solids pump
KOS 5100
q Many representatives from the
Chinese regional government and
industry representatives took part in
the official naming ceremony of the
“Guohai I”.
(4th from the right) Gerhard Schäffer
from PSP
44
At exactly 9:09 am on 6th June, 2010, the
ship “Guohai I” (Chinese Sea) was named
and launched at the port of Rongcheng (in
the province of Shandong) in an official
ceremony.
This dredger from the Chinese manufacturer Guohai Meister (a co-operation partner of Putzmeister Solid Pumps GmbH)
is the first dredger that has integrated a
KOS 25100 piston pump and transports
the sludge in a closed pipeline.
The dredging sludge can be pumped
across longer distances using a lower water content and this accelerates the process of land reclamation considerably.
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In brief
In brief
Putzmeister at construction sites in India
45
Climbing booms and stationary pumps
at the Ruby Mill Tower in Mumbai
At the Ruby Mill construction site in Mumbai, two MX 32-4T self-climbing stationary booms and two pumps of the type BSA
1408 HD are being used. In total, 50,000
cubic metres of concrete has to be placed.
The pumps are cleaned using sponge balls
and wash-out pigs by simply pumping them
with water. There is no need for any separate
cleaning station.
1,100 m of concrete is used for each level, including the ceilings, columns and inner walls. Two levels are completed each
month.
3
Concreting data
Concrete
type
Compressive
strength
Slab
M 40
> 40 N/mm2
Column
M 50
> 50 N/mm2
Inner wall
M 50
> 50 N/mm2
Slump measure (ø)
140 mm
Concrete delivery
pressure
200 – 220 bar
46
Ruby Mill Tower
Once complete, the Ruby Mill Tower will
be 185 m in height and have 34 levels
(four of which are parking areas). The total usable area of 78,000 m2 will mostly
be used as office space.
The building was designed by the New
York architects FxFowle, analysis and
design was carried out by LERA and the
Indian company Vascon Engineers undertook the construction of the building.
Construction commenced in 2007 and
the building should be complete by the
end of 2010.
48
Essar Oil Refinery in Jamnagar: Four truck-mounted
concrete pumps in action
Essar is using the first Putzmeister M 42-5
in India to concrete one of the largest refineries in the world at Jamnagar in West
India. Together with three of the eight
M 36 pumps from the fleet, the “new” edition pumps reliably throughout the day
and night.
The Putzmeister India After Sales & Parts
Service is regarded highly by the people at
Essar, but the message from Deepak Kumar
Singh, Managing Director of Essar HED, is
clear: “For me, the machines by Putzmeister
are simply the best for concreting.”
47
p Teamwork: Three M 6 and the new
M 4-5 are placing 1,400 m of concrete
Essar Oil
The Essar Oil Refinery in Vadinar/Jamnagar in the state of Gujarat lies on
India‘s west coast, ideally located close
to the oil-rich Gulf states. It is one of the
largest refineries in the world.
The Indian conglomerate, Essar Group,
is active in the fields of steel, oil and gas,
energy, communication, transport/logistics, construction and raw materials.
PM 4307 GB
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Safe. Clean. Simple.
The new Pin Pour
50
49
Work safely and cleanly!
• Stop dangerous goosenecks!
• The boom is steadier –
constant flow of concrete, even at low output
• No risk of injury from concrete splatters
Reduce your operating costs!
• Quick and easy assembly
• Less wear of delivery line pipe and end elbow
• Economic
• Affordable
51
for all end
hoses with
Ø 125 mm
Order now: Phone +49 (0) 173 3 09 26 63 · spareparts@putzmeister.de
Hotline for technical questions: +49 (0) 7127 599-297
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