t

s
o
P

The magazine by Putzmeister Concrete Pumps GmbH

How long do truckmounted concrete

pumps last?
Telebelt at the thirdlargest embankment
dam in the world

With a tunnel concreting

train in the city tunnel of
Malm

80

The 4h pumping of

Neufahrn: Large boom
team places concrete at
motorway interchange
PM 4356 GB

Content

Content / worth knowing

2

Title story
Munich: Motorway interchange at Neufahrn
24-hour concreting with two large booms

Exhibition
dates

On site

January April 2011

Five of the largest stationary booms in the world used for the job
Large construction site in central Russia relies on
Putzmeister equipment

18. 21.01.2011
WOC World Of Concrete,

10

China: Telebelt conveys concrete for dam project

The third largest hydro-electric power plant in the world arises

08. 11.02.2011

14

50 questions
How long do truck-mounted concrete pumps last?
No old iron here veterans on the construction site

Las Vegas/USA

12

bC India, Mumbai/India
22. 26.03.2011

Less traffic jam:

A motorway interchange
is being reconstructed

ConExpo, Las Vegas/USA

06. 08.04.2011
USETEC, Cologne/Germany

By the way

Underground
Sweden: on track with Putzmeister in the Malm city tunnel
Tunnel concreting train enables precise concreting
of the slab track

In 2009, a total of 1,338 customers

took part in 74 Putzmeister Academy seminars, with numbers growing all the time.
Over a lengthy period, concrete
pump owners have observed the
effects of their machine operators
undertaking training sessions with
resulting qualifications on their accident frequency and costs. The results show clearly that investment
in training pays off.

18

In brief
Governor of Baghdad visits Putzmeister
Perilous ride on the wild buffalo
An unusual tourist at the North Cape

22
22
23

12

You may well ask:

How long do
concrete pumps last?

14

More power: Telebelt

places concrete for
hydro-electric plant

Imprint:

Worth knowing
Exhibition dates / Interesting facts

Photo credits
Imprint

Editor:
Putzmeister Concrete Pumps GmbH
Max-Eyth-Str. 10
72631 Aichtal Germany

3
2
3

Photo credits:
Unless indicated otherwise, all illustrations are copyright
Putzmeister Concrete Pumps GmbH.
17: Kernkraftwerk_Nowoworonesch_II, Wikimedia Commons, licensed under CreativeCommons license by-sa3.0, Rosenergoatom 24: China_edcp_location_map,
Wikimedia Commons, licensed under CreativeCommons
license by-sa-3.0, Uwe Dedering 25: Putzmeister Machinery (Shanghai) Co., Ltd. 34: Citytunneln_karta,
Wikimedia Commons, licensed under CreativeCommons
license by-sa-3.0, Rjaber 40: Feste_Fahrbahn_FFBgl,
Wikimedia Commons, licensed under CreativeCommons
license by-sa-2.0, Jailbird 45: www.demis.nl 46: Nordkapp_2010, Wikimedia Commons, Hapesoft

PM 4356 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
Trnkestr. 17
70597 Stuttgart Germany

PM 4356 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 (3.51012)

worth
know
ing


Title story

Title story

4-hour pumping at Neufahrn:

The large-boom team concretes
at the motorway junction
6

Position M 6-6

Munich

Position M 58-5

City
Munich

On the morning of 4th August, two largeboom concrete pumps arrived at the Neufahrn motorway junction north of Munich
one M 58-5 from Berger Beton and one
M 6-6 from BFM Betonfrderdienst in
Munich.
A sunny, almost autumnal day announces
itself with hazy, mild air and single wisps
of low cloud. The weather will stay beautiful perfect for the planned 4-hour
concreting that is due to take place today.
One notices the men on the construction
site are in a good mood the best prerequisite for starting the work and for the
challenging task that lies ahead of them.
Narrow junction at Neufahrn
This structure, which, when viewed from
above, looks like a atly pressed four-leaf
clover, can no longer cope with todays traffic
volumes. Two national motorways intersect
at the Neufahrn junction the A 9 and the
A 92. Along with the Munich motorway
ringroad (A 99) and the A 8 Ulm-MunichSalzburg, the A 9 is the most important north-south route, especially for domestic and
international commercial and holiday traffic.
The A 92 connects the state capital of Munich with its airport and is also important
for Eastern European traffic.
8

p The M 6-6 on the north-western

ramp at the motorway junction

View of the construction site from the southern ramp.

The column for the nd bridge section has already been formed.
4

Title story

Title story
9

The average volume of traffic from the airport towards Munich is currently approximately 24,000 vehicles in 24 hours. An
average daily traffic ow of approximately
38,000 vehicles in 24 hours is predicted for
the year 2020. On average, that would be approximately 1,600 vehicles travelling via the
Neufahrn junction per hour not to mention
rush-hour traffic.
Large-scale reconstruction is required
In view of this projection, the only option is
a speedy connection via the existing motorway junction using a direct ramp. The current single-lane exit via a quadrant of the
clover will be completely replaced by a so-

Flyover concreted in two sections

called yover that channels a two-lane carriageway from the A 92 to the A 9 towards
the south.
The customer is Autobahndirektion Sdbayern and the contractor is Hentschke Bau
GmbH in Bautzen.
The construction work at the Neufahrn motorway junction commenced in April 2009
with the reconstruction of a connecting
ramp and the spillage that is required to
build the new bridge, with 110,000 cubic
metres of delivered soil. In 2010, comprehensive excavation and ceiling work took
place at the Neufahrn motorway junction,
as well as bridge construction work in the
whole area. The construction project should
be complete by the end of 2011.
p Dipl.-Ing. (engineering masters) Felix
Raschke, site manager for Hentschke
Bau GmbH, the company commissioned
for the project

Back to the concreting at the yover: Dipl.Ing. (masters in engineering) Felix Raschke,
the site manager, explains: Today, we are
concreting section 1 of the Flyover.That is
the longer stretch, at 120 m. We started work
on the carcass in February of this year and
the construction work will continue until October. After that comes the 2nd section the
road section that is 80 m long.In answering
the question about the particularities of this
motorway construction site, he responded
saying that the scaffolding work could only
be carried out at night. It was extremely important that the motorway was completely
closed for this work and the strict compliance with closing times applied here.

Concreting commenced at 6 a.m. Each of

the two truck-mounted concrete pumps
stands fully-supported at the foot of one of
the construction columns within one of the
northern clover quadrants of the motorway
junction. From this location, they pump concrete to the sites of concrete placement on
the approx. 12 m high bridge. Meanwhile,
the traffic ows freely on the circular paths
of the exits and under the structure.
At the beginning, the end hoses of both booms
and the respective machine operator of each
concrete pump met in the middle of the bridge
construction site. From there, each of them
works outwards.The horizontal reach of the

large boom is fully utilised. The high level of

exibility of the 6-arm or 5-arm boom was an
important criteria for the managing directors
of BFM and Berger when they were making
the decision for a new large boom. When used
together with the sensitive Ergonic control,
the strengths of two booms can be fully utilised in a situation such as this.
The M 62-6 from BFM and the M 58-5 from
Berger Beton have the longest horizontal
reach of any pumps across Bavaria. With
each having eets of more than forty concrete
pumps, both of these companies are among
the largest service providers in the state of
Bavaria.

q The pumping duo started the concreting in the centre of the 10 m bridge.
From there, the booms move away from each other as they work.

q In a good mood and with everything under control:

Harry Kirchmaier drives the M 6-6 from BFM and Stefan Vogel drives the M 58-5
from Berger

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Title story

In 24 hours, a total of approx. 2,000 m3 of

concrete C40/50 was placed with a compressive strength of 42.5 N/mm2 (exposition
classes XC4, XD1, XF2). This is the quantity
of concrete for the entire cross-section of the
structure of section 1 including footbridges
and carriageway slabs (see the box containing data about the concreting). The complete superstructure (sections 1 and 2) will
contain 3,400 m3 of concrete.
So that traffic can ultimately travel on the
road comfortably and safely, the finished
concrete surface receives another 8 cm thick
layer to the overall construction. The concrete is first primed and completely sealed
using epoxy resin. An asphalt sheeting (0.5
cm) comes next and then a protective layer
of mastic asphalt (3.5 cm thick). Finally, the
surface of the road is formed by a 4.0 cm
surface layer of stone mastic asphalt. n

Title story

Technical data of the concrete pumps on site

Folding type

M 58-5

M 6-6

5-Arm roll-Z-fold

6-Arm roll-Z-fold

57.6 m

61.1 m

53.6 m gross

57.1 m gross

49.4 m net

52.4 m net

42.4 m

44.3 m

Vertical reach
Horizontal reach
Reach depth
Unfolding height
Delivery line

Properties of fresh concrete

12.3 m
DN 125, max. 85 bar

normal
OSS

front /

rear

C40/50

Exposition classes

XC4 Changing wet and dry (e.g. exterior components with direct

Exposition classes
and what they mean

exposure to rainfall, components in water tidal zones)

XD1 Moderate moisture (e.g. components in areas where water
may spray from traffic areas)
XF2 Moderate water saturation with de-icing agents (e.g. concrete
components in areas where water may spray from traffic

23 m
Arm 1, 2
Arm 3, 4, 5, 6

Support width

Strength class

areas that have been treated with de-icing agents)

DN 125, max. 85 bar

DN 117, max. 85 bar
front /

rear

approx. 11.1 m / approx. 11.5 m

approx. 12.1 m / approx. 12.3 m

approx. 8.7 m / approx. 8.0 m

approx. 8.8 m / approx. 8.3 m

Steel used
Untensioned reinforced steel

280 t

Prestressing steel

107 t

Thickness of the layer of placed concrete

in the area of the webs

q In the middle of the motorway but nevertheless secure: The concreting is carried
out quietly while the traffic can ow freely under the bridge construction.
This photo shows the M 58-5 on the north-eastern ramp.

12

2.40 m

in the centre of the carriageway 0.35 cm

13

t To determine the water content, the

concrete is heated up until it no longer
contains any liquid.The difference in
weight can be used to determine the
water content.

q After a quick clean, the truck mixers

rejoin the queue of motorway traffic in
order to fetch more concrete

14

To ensure that the durability is sufficient, concrete components must be strong

enough to withstand chemical and physical impact on their environment and
their use. The impacts from the various
environmental conditions are classified
into exposition classes that may have an
impact on the concrete, the reinforcing
steel and metallic components and that
are not accounted for as loads during
the constructive assessment. From this,
the requirements are derived for the
composition of the concrete to be used,
as well as the concrete cover and the
permitted crack width.
The designations for the individual exposition classes are made up of the letter X (for exposition), the identification
for the type of damaging effect and a
number that denotes the intensity of the
damaging effects. The following abbreviations are used from English for the
various types of effects:
0
C
D

for zero risk (no risk of attack)

for carbonation
for de-icing salt (chlorides that are
capable of changing, e.g. from deicing salt)
S for seawater
F for frost (frost and de-icing salt)
A for chemical attack
M for mechanical abrasion, wear, or
similar
The strength of the relevant ambient
condition is assigned a classification
from 1 to 4.
In Germany, the exposition classes are
regulated by DIN 1045-1 (08-2008).
In contrast to the previous version from
2001, the effect W concrete corrosion
due to alkali silicic acid has been added
to the exposition classes. No minimum
concrete strength class is assigned to
this exposition.
[Source: wikipedia.de, licensed under
http://creativecommons.org/licenses/by-sa/3.0/deed.de.]

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On site

On site
16

Five MXKD 50 at a major nuclear power

plant construction site in central Russia

17

15

Five of the largest stationary booms in the

world Putzmeister MXKD 50 are taking
part in the construction of the Novovoronezh
NPP-2 nuclear power plant on the banks of
the Don river. At the end of 2009, Putzmeister
was awarded a contract to provide the equipment for concrete distribution at the reactor
block: Five placing booms with a horizontal
reach of 50 m (fitted on Manitowoc/Potain lattice towers up 50 m tall), two BSA 2110 HP-D
stationary concrete pumps and a 300 m
ZX 125 delivery line.
At the start of 2010 and on a total of 10
tautliners (trucks that have a sliding curtain
for crane loading), the disassembled booms
travelled from the factory in Grndau to
Putzmeisters Russian headquarters in Moscow. From there, the booms travelled on to
the site of use, approx. 500 km further south
in Novovoronezh. n

Novovoronezh-II-1
Reactor type

WWER-1200 (AES 2006)

Power

1,085 MW (net)
1,170 MW (gross)

Start of construction
Commissioning
Operator

p Disassembled and loaded: A total of ten trucks rolled on to Russia

20.06.2007

planned for 31.12.2012

Rosenergoatom

p Autumn 010: Technicians from Putzmeister RUS travelled from Moscow and
are currently installing the concreting equipment at the huge construction site.
q With a horizontal reach of almost 50 m, the MXKD 50 is the largest stationary boom in the world on site

18

Technical data MXKD 50

Number of arms
Folding type
Horizontal reach

4
Roll fold
49.9 m gross

Reach depth

39.2 m

Vertical reach

46.5 m

Weight

10

37,550 kg

11

50 questions

Technology Question 26

How long do truck-mounted

concrete pumps last?

50 questions

26

21

19

Even Putzmeister engineers continue to

be surprised by how long truck-mounted
concrete pumps can be in service: some
machines have almost 40 years of service under their belt.
Luckily, Putzmeisters Services department
employs true experts when it comes to spare
parts for old truck-mounted concrete pumps:
Our computerised spare parts management
only began in 1983. Before then, everything
was done in our heads or was found in old
documents.
Several times a month, we receive requests
that can only be solved by human intelligence. One such example is the water-hydraulic driven concrete pump B232, manu
factured in 1971. To put this machine out of
service has never crossed the mind of the
Polish entrepreneur Grzegorz Kujawski. He
regularly orders new spare parts.
What makes truck-mounted concrete
pumps grow old
Three factors determine the service life of a
truck-mounted concrete pump:
how the machine is serviced and
maintained,
the number of hours that it is in
operation,
and the quantity of concrete that is
pumped.

12

p B232/39 years old/Poland

This water-hydraulic driven concrete pump B232 has been in use since 1971. Even in
2008, it was still pumping a daily volume of 150 cubic metres of concrete.

According to the requirements that

Putzmeisters engineers are given, the
truck-mounted concrete pumps should be
able to keep working for at least 10 years.
The critical factor here is the design of the
placing boom. During pumping operations,
the boom is particularly stressed by the
load shifting. The number of load changes
is determined by the pump output and the
operating hours.

Anti-aging past and present

In the past, designers could rely upon their
knowledge and experience and consult with
others regarding standards and regulations.
If there was any doubt, they increased the
strength of the material at heavily-used
points on the placing boom. As early as the
end of the 1970s, Putzmeister owned a test

q M 45-5/22 years old/Austria

This M 45-5 worked almost 12,000 operating hours over 20 years before getting a
new owner.

20

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p M 31-3/27 years old/Cyprus

This M 31-3 Triplet that was manufactured in 1983 is still in top form. For its 26th birthday in 2003, it underwent a major overhaul and was affectionately given the name Our favourite grandmother, which was prominently displayed on the boom.

rig to simulate long periods of use. If the

boom passed the test, the design could go
into series production. In practice, something
became clear: The machines keep working
for considerably longer than 10 years provided that they are well maintained. As is
the case with the machine from Poland.
Since the beginning of the 1990s, the designers have used finite element analysis

(FEM) to precisely calculate the stress on

the components. A screen in the software
programme shows the tension that will later
appear in the material and shows the critical points. The design, material and material
thickness can then be optimised. Using a
new boom test rig, the engineers can simulate years of the life-cycle of the boom at
high speed.

q M 46-5/7 years old/China

Since 2003, this M 46-5 has pumped an annual volume of 90,000 m3 in Shanghai!
That is three times more than the same machines in Europe.

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22

Practical test in China

How well do the computer-optimised designs
actually work in practice? There are no machines that are 40 years old yet. However,
there are truck-mounted concrete pumps
that have worked considerably more than
you would assume from their year of manu
facture.
In China, young machines are already old.
The M 46 shown (year of manufacture:
2003) has worked non-stop since its delivery: pumping volumes of 90,000 cubic metres
of concrete each year are the norm at peak
times, the pumping volume increases to
up to 12,000 cubic metres of concrete each
month. By comparison: In Europe, large
boom truck-mounted concrete pumps deliver approx. 30,000 cubic metres of concrete
each year. In terms of European machines,
this machine has already survived the required 10 years well and it continues to
run and run and run. n

13

24

On site

On site
23

The longest river in Asia

with the changing name

The tributaries feed the Yangtze with large

quantities of sand, silt and clay an annual
quantity of approximately 680 million tons,
which is as much as the Nile, the Mississippi and the Amazon together! This makes the
Long River one of the most sediment-rich
rivers in the world. Where it is damed like
at the huge Three Gorges Dam the ow
velocity of the water slowes down, sediment
is stored in the reservoir and gradually silts
up. The Xiluodu dam should counteract this.
It is expected that the dam should reduce
the quantity of sludge in the Yangtze by a
third.

The 6,300 km long Chang Jiang (also

known as the Yangtze - the Long River) is
the longest river in Asia and, after the Nile
and the Amazon, is the third-longest river
in the world. It originates as the Dri Chu
(Tibetan river of the female yak) from the
Ganjajubu glacier at an altitude of 5,405 m
and continues under the name of Jinsha
Jiang Gold Sands River from north
to south along the entire border between
Sichuan and Tibet. In the Hengduan Mountains, it crosses the border between Sichuan and Yunnan. From the city of Shuifu, it
ows under the name of Yangtze until it
reaches the East China Sea to the north of
Shanghai.

Mammoth producers
of energy
Once completed, the Xiluodu hydro-electric
plant will produce 12,600 MW of power.
This means that, with regard to power
plant capacity, it would be the secondlargest hydro-electric plant in China after
the Three Gorges project and the third-largest in the world. The China Yangtze Three
Gorges Project Development Corp. is plan-

The dam should reduce

sludge load
In the Red Basin, the Yangtze is fed by numerous tributaries that drain, for example,
the eastern slopes of the Tibetan highlands.

TIBET

Jiang

14

The devices in the Xiluodu dam that are

planned for ood water ow include seven
overow drainage openings at a size of 12.5 m
x 13.5 m, below them eight outlets at a size
of 6 m x 6.7 m and four exceptionally large
overow tunnels (with a diameter of up to
15 m) two tunnels on the right embankment and two more on the left. The overow
capacity of the project amounts to up to
49,923 m3/s. The power that is generated by

In valleys that are very high and narrow,

the preferred dam to build is the arch dam.
The wall forms a vertically and horizontally tensioned arch towards the side of the
water. Due to the arch-shaped design that
is directed against the ow of the river, the
mass of water is distributed over a larger
surface area and therefore puts less stress
on each unit of area. Signicantly fewer
materials are required to construct these
dams than are required for other types of
dams. However, the water pressure is diverted over the arch to the foundations in
the mountain at the side. The attachment
to the rock is therefore particularly important with this wall design.

Yangtze

Jinsha

A double-curved arch dam should dam up a

storage lake of 12.67 billion m3. The absolute
elevation of the dam crest is 610 m, the maximum height of the dam is 278 m and the
overall length is 700 m. The total excavated
material for this project amounts to 39.81
million m3 of which 25.61 million m3 is above-ground excavation and 14.20 million m3 is
from the construction of tunnels.

In total, 16.72 million m3 of concrete is required for this project and 6.60 million m3 of
this is required just for the body of the wall.
The concreting work commenced in 2008. It
is expected that the rst generator sets can be
installed in June 2012. From June 2013, the
rst electrical energy should be generated
and the entire project should be completed
by 2015. US$ 7.36 billion has been invested
in the Xiluodu hydro-electric plant.

Special conguration:
Arch dam

AU

g
kon

At the Jinsha River a tributary of the

Yangtze the Xiluodu hydro-electric
plant is currently being built. Its main
purpose is to generate electricity but it
also fulls other tasks: ood protection,
deposition of sediment, improvement of
shipping conditions, etc. It is expected
to produce from 57 to 64 billion kilowatt
hours of electrical energy each year,
making this plant the third largest hydroelectric plant in the world.

BE

P L AT E

Me

Telebelt conveys enormous masses

of concrete at the third-largest
embankment dam in the world

TI

N
TA

ning three more giant hydro-electric plants

at the overow of the Yangtze, namely Wudongde, Baihetan and Xiangjiaba. At 38.5
million kWh each year, their combined
power generation should be double that of
the Three Gorges Project.

SICHUAN

Three Gorges
Dam

Xiluodu
Dam

the overows is almost 100 million kilowatts

and is therefore the highest in the world. The
four overow tunnels are the largest of their
kind in the world and have a discharge rate
of 16,000 m3/s, which is about a third of the
entire outlet capacity of the plant.

China
25

YUNNAN

The water quantity and ow rate place

high demands on the concrete
These numbers are not just attributed to the
size of the tunnel but also to the ow rate
of the river, which is amongst the fastest in
the world (up to 50 m/s). Since these four
overow tunnels were designed to cope with
exceptionally large quantities of water at an
extremely high ow rate, the concrete that is
used here must be of outstanding quality. The
difference between this concrete and a pumpable concrete mix lies mainly in the proportions of the individual concrete raw materials

PM 4356 GB

that are used. Pumpable concrete requires a

relatively high owability so that it can ow
through the delivery line. This means that
concrete raw materials such as cement and
y ash are required in large quantities. However, cement creates a lot of hydration heat
when setting the concrete, meaning that the
temperature and crack formation are difcult
to control. The dissipation of the hydration
heat may pose a problem, particularly with
structures such as a dam.

PM 4356 GB

Telebelt comes out ahead

Telebelt is a mobile belt conveyor that can
continuously convey any kind of bulk materials and concrete and is unrestricted by the
pumpability of the concrete. Telebelt is therefore the perfect solution for pouring highquality mass concrete as it not only means
that fewer cracks are formed but it also reduces the costs for the concrete.

The rst Telebelt TB 105 delivered by

Putzmeister has been used in the Three
Gorges Dam project since the year 2000. To
date, the number of operating hours amounts
to more than 20,000 hours and the device
continues to work properly clear proof of
the robustness and reliability of the Telebelt.
Due to this experience, the company responsible for the Three Gorges project ordered
two more Telebelts of the new type TB 110G
for the team from SinoHydro Bureau 7. Since
15

On site

On site
26

28

the machines are very convenient to operate

and the boom can be gently and smoothly
telescoped, swung, lifted and lowered, the
two TB 110G devices are very popular on the
construction site. The machine has evoked
a positive response among the workers from
SinoHydro Bureau 7: Concrete pouring has
become childs play. However, if we look at
the quantity of concrete that the Telebelt
must continuously pour for each concreting
more than 1,000 m3 of concrete it becomes
clear just how hard the work is for the workers on the construction site.
Telebelt is in great demand across the
entire power plant construction site

p Telebelt being used to concrete the cable crane platform

q Telebelt is placing concrete at the gate of a tunnel

The Xiluodu hydro-electric plant is a huge

construction site. Several projects are ongoing at the same time and these are co-ordinated centrally. The individual construction
teams work closely together.
It is often the case that immediately after one
concreting task has nished, the belt conveyor travels to the next site of use on the
construction site. Thanks to its high levels of
exibility and mobility, the Telebelt is often

used on the front line. The TB 110G from

Putzmeister was therefore not only used on
the construction sites of SinoHydro Bureau 7
(in other words, to construct the overow
tunnels, the foundations of the cable crane
structure and for above-ground concreting,
etc.), but it also considerably helped the
construction sites of Hydro Bureau 6 and Hydro Bureau14 (among others) when constructing the surge tank, the underwater outlet,
the main transformer building etc. As a result, on one occasion, the Telebelt was used
on ve different construction sites within
six days, during which time it continuously
placed 4,800 m3 of concrete for the overow
tunnel, the cable crane platform and the underwater outlet. The high level of efciency
demonstrated by the belt conveyor is another
performance feature that is recognised on
the construction site. For example, the TB
110G generally requires only 2.5 minutes
to drain a mixer of 6 m3 for the work on the
cable crane platform and, at a slightly higher
speed, it requires only 1.8 minutes to drain
the mixer. This extremely high machine output signicantly contributes to completing
the work within the scheduled time.

27

29

p Telebelt pumps concrete for the

overow tunnel
u The aggregate in the concrete that is
used is up to 60 mm. A pump doesnt
stand a chance, but its a feast for the
Telebelt.

30

Greater versatility with Telebelt in

semi-trailer conguration
Chassis versatility meets local weight
restrictions

Greater mobility on-site

Material placement does not rely on the
chassis engine
Promotes lower operation costs and
reduced fuel consumption

Tandem Dolly available to move

Telebelt semi-trailer on-site with a
dozer, wheel loader or other available
equipment

31

16

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32

Underground

Underground
33

p A locomotive with the rail wagon

shuttles between the concrete handover
point and the concreting train

t The concreting train with electrically

operated concrete pump, which is fed
via a conveyor belt
34

With the Special train to Sweden:

A slab track system is being
created in the Malm city tunnel
A slab track is being laid in the tunnel
section with two individual 6 km tunnels.
The sleepers are embedded in concrete
and can absorb the vibration caused by
high-speed trains in a better way due to
having an extremely exible insert.
Maximum precision is required when the
tracks are installed. The sleeper shoes
that have been freshly embedded in the
concrete must not be subjected to vibration. Even the slightest variations in the
alignment of the tracks can result in the
railway no longer complying with the original designs for high-speed travel.

18

The order for constructing the slab track

in the Malm city tunnel was placed with
Rhomberg Bahntechnik GmbH.
The objective was to find a solution for installing the concrete track bed over a distance
of two times six kilometres without a major
amount of vibration. The plan was to do the
concreting at a speed of 15 20 m/h.
Railway engineering specialist Rhomberg
(based in Bregenz in the Austrian Vorarlberg
area) made contact with the representative
of Austrian company Putzmeister, Hans Eibinger GmbH. Together with the Concrete
Project Division department at the main
Putzmeister plant in Aichtal, all of the par-

Fast connection: Malm city tunnel

The city tunnel is a section of railway that is under construction in Malm/Sweden with an overall length of approx.
2 x 6 km.

ties involved collaborated to produce a solution for supplying a tunnel concreting train
based on the patented installation solutions
of Rhomberg Bahntechnik.
Comprehensive planning

The tunnel is intended to connect the rail traffic

from Sdersltt with the resund rail traffic,
turn the Malm C main station into a transit
station, relieve the strain on the Kontinentalbanan and increase the catchment area of
the resund rail traffic.
The tunnel is being opened on
04.12.2010.

www.citytunneln.com/en/

During the planning of the tunnel concreting

train it had to be taken into consideration
that the freshly embedded sleeper shoes
could only bear a certain amount of load.
Beginning with the setting speed of the concrete and the travel speed of the concreting
train, it was calculated that a distance of between 250 and 400 m had to be maintained

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The projects website (english)

Route:
Red = Tunnel section under construction
Yellow = Surface railway section under
construction
Grey = Completed sections

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19

Underground

Underground
35

36

Pre-deployment test run

An initial test run of the tunnel concreting train for constructing the slab track
in the Malm city tunnel took place on
06.08.2009 at the Rhomberg Bahntechnik test site.

p The main power supply is provided

by a diesel unit with output of approx.
400 kW that is equipped with a soot
particle filter for operating in the tunnel.

During the test run, 10 m3 of concrete

was laid in the prepared track bed using
the concreting train. A stroke time of 4.2
seconds was determined during the pumping process, which represents a delivery rate of approx. 38 m3/h. The hydraulic
pressure reached a maximum of approx.
215 bar when this took place. Starting

In order to simulate the situation on site

as realistically as possible, part of the
slab track in Malm was modelled in
Dornbirn/Austria. The sleeper shoes of
the rails were embedded in concrete (see
fig. below).
The mixer drum was fed with fresh concrete with a truck-mixer pump during the
test.

38

39

A slab track (previously also referred

to as a ballast-less track or ballast-less
superstructure) is a railway line that is
used in railway, road and underground
train construction in which the ballast
and the sleepers are replaced with a solid track structure made from concrete or
asphalt.

At speeds of more than 200 km/h, it is

particularly important to note that, as
well as having better track stability, the
maintenance costs of the slab track are
significantly less. It is more resistant to
deformation and the effects of the weather, and track position problems (and
therefore speed restriction sections) hardly ever occur. The slab track is expected
to have a service life of at least 60 years.
This increases the availability, reliability
and profitability of the railway line.

37

p The patented concrete paving machine when embedding the sleeper shoes

between the concrete paving machine and

the pump unit. The entire pipeline would
therefore have to be made mobile. The pump
unit consists of an electrically powered concrete pump and two mixing drums, whereby
the first one would be used to supply the
system with fresh concrete, and the second
one would provide the concrete for ensuring
that a continuous concreting cycle could be
maintained.
Concreting train
The concreting train consists of various railway wagons on which all of the necessary
components for carrying out a continuous
and smooth procedure are mounted (including the necessary cleaning and maintenance
work). All systems are protected by an emergency power unit.

0

Pump and delivery line

The Putzmeister stationary concrete pump
is on the third wagon, plus a small conveyor
belt for feeding the concrete pump. In order
to prevent the pump from drifting during
the pumping procedure, the frame of the rail
car is filled with concrete and the support
legs of the pump are directly screwed to it.
The pump can be operated using a cable-connected remote control during the pumping
process. The concrete is transported from
the pump to the concrete paver up to 400 m
away via a steel delivery line that is installed
on special wagons. The maximum permitted
concrete pressure of the delivery line is
130 bar. The delivery line has a diameter
of 125 mm and a wall thickness of 7.1 mm.
Since the slab track in the Malm city tunnel
also has a long curve with a radius of 760 m,
the line has been adapted accordingly in

p The concrete pump is screwed to the

superstructure of the railcar

order to be able to run on the patented alignment system made by Rhomberg Bahntechnik. Non-critical load transmission was
a challenge during dimensioning.
Paving machine
The patented paving machine is located at
the end of the delivery line and consists of
an upstream working and transport platform
and a hopper. The concrete is transported to
the track bed via three special chutes. The
concrete is pre-smoothed using skimming
boxes and then compressed using vibrators.
Cleaning
Particular attention was also paid to having
an environmentally friendly disposal and
cleaning concept that meets the strict regulations in Sweden. In order to clean the

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delivery line with water, a media separating

device must first be installed. This ensures
that residual concrete and washing water do
not mix. The residual concrete in the line can
therefore still be laid in the track bed. The
media separation system consists of the combination of sponge ball soaked cement bags
sponge ball wash-out pig sponge ball.
Team success

with a conveying distance of about 250 m,

this results in a calculated friction coefficient of 2.6. No more than 25 30 m3/h
is required in the actual pumping process
in Malm, meaning that the required delivery capacity is therefore provided.

Slab track system

40

It was possible to successfully deal with this

complex project by means of close collaboration between participating project partners
Rhomberg, Eibinger and Putzmeister. Not
least the competent service engineers from
Eibinger and their involvement, along with
the efficient service contributed to the success of this new solution for supplying concrete. n

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1

In brief

In brief
44

The Governor of Baghdad, his Excellency

Salah Salem Abdelrazaq Al-Hameed, paid
a visit to Putzmeister on 22nd September.
As the representative voted by the people,
he enjoys the status of a minister, and governs the Governorate of Baghdad. The
delegation was accompanied by representatives of Liebherr, our partner firm
in Iraq.

The visit was taking place because of concrete plans by the local government for the
production and pouring of concrete by staterun construction firms in infrastructure projects carried out by them. A visit to the plant
and demonstration of a BSF 58-5.16 H truckmounted concrete pump were therefore on
the programme. Having a go at operating it
clearly pleased the Governor.

Governor of Baghdad
visits Putzmeister
41

An unusual
tourist
at the
Nordkapp

As well as Putzmeister, the delegation

also visited the companies Liebherr and
Bomag. The trip was filmed and will be
shown on Iraqi television.
Putzmeister has been successfully active
in Iraq for over 25 years. There are currently more than 100 Putzmeister truckmounted and stationary pumps working
in Iraq to help with rebuilding the country.
q The easy operation of the M 58-5
via remote control clearly pleased the
Governor

42

43

Perilous
ride on the
wild buffalo
It goes without saying that the solution shown here
in no way meets the applicable safety regulations: A truck
mixer feeds a truck-mounted concrete pump. As usual. The
pump in its turn feeds the hopper on a shotcrete machine. Fine too. The shotcrete
machine is suspended over 10 m
in the air from a truck-mounted
crane, and is manned by two
daring machine operators.
One of them sits on the
hopper by the end hose,
the other controls the
spray arm. Strange and
dangerous! Not exactly a
prime example of slope
reinforcement! Well, at
least the men had their
hard hats on.



The Pumi 31.89 S owned by the Norwegian company Arnesen Beton AS had a long
trip to its destination: a round trip of 470
km in total, from the works in Alta to the
Nordkapp, and back again. Once there, it

was used to renew the foundations of the famous sculpture. Not a huge job, but a nice
one! according to Pl Vidar Arnesen, Production Manager.

For over 30 years, Arnesen Beton has been

supplying and pumping ready-mixed concrete in Norways northernmost regions.

Norways North Cape the northernmost point in Europes road network

metres. It counts among the deepest and

steepest of tunnels in parts, it encounters
inclines of 9 %.

Tourism with tradition

The Nordkapp is a shale plateau on the

Norwegian island of Magerya, rising
sheer from the Arctic Ocean. It lies at
71 10 21 north, some 520 km north
of the Arctic Circle. Since being linked to
the road network in 1956, the Nordkapp
has been the northernmost point in Europe that can be reached by car from the
European continent.
Since 1999, the island of Magerya has
been connected to the mainland via the
Nordkapp Tunnel. The tunnel is 6,875
metres long, burrowing under the Magery Sound at a maximum depth of 212

45

In 1845, with the first arrival of the

Prinds Gustav steamer from Hammerfest, the Nordkapp had its first taste of
tourism. The first organised group tours
from London were arranged by the
Thomas Cook travel agency in 1875.
It was not until 1893 that the Nordkapp
made its real breakthrough as a tourist
destination, when the Hurtigrute, the
first permanent sea route along the coast
to the North, was established. Today, the
Nordkapp is a tourist destination with
around 200,000 visitors per year.

www.nordkapp.no
46

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Putzmeister Services information

Change to single piston

and save money
47

Costs in
9,000

Compact
piston

8,000
Replacement
interval
compact
piston:
15,000 m3

7,000
6,000
5,000

Replacement interval
single piston:
40,000 m3

4,000

Single
piston

,000
,000
1,000

50,000

100,000

150,000

00,000

m pumped

Calculation based on empirical service life of 40,000 m3 for 230 diam. single pistons, and 15,000 m3 for 230 diam. compact pistons

Changing from compact pistons to

single pistons will reduce your costs
by more than 50 %
Putzmeister single pistons are more
cost-effective under all conditions of
use, because they have been proven to
have a service life that is 2 to 3 times
longer than that of compact pistons.
One-off conversion costs
Particularly suitable for higher
pressures and abrasive concrete

48

Reduced consumable costs and

shorter downtimes on your machine
Even some machines from
other manufacturers can be
equipped with Putzmeister
single pistons

Additional information is available from:

Phone +49 (0) 7127 1019 spareparts@putzmeister.de
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