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Muller Crane Suspended Vibrators
Muller Crane Suspended Vibrators
ThyssenKrupp
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CONTENTS
MLLER-vibrators for driving and extracting. Selection and key data. MLLER-vibrators (H series). MLLER-vibrators (HHF series). MLLER-vibrators (HFV series). MLLER-power packs and control system. MLLER-clamping devices and safety grippers. MLLER-attachment vibrators. Excavator-mounted vibrators Leader-mounted vibrators MLLER-drill drives. Data logging systems. Special applications. 3 4 6 7 8 9 10 11 11 11 12 13 14
Suspension
Pile
Choosing the right equipment is key to the economic and technical success of any vibration driving job. Parameters such as the size and drive output of the vibrator must be matched to the length and weight of the pile and the soil conditions.
In particular MLLER-vibrators with resonancefree starting and infinitely variable amplitude as well as two-in-one vibrators (HHF series) with stepwise variable amplitude and frequency are suitable for virtually all applications. For straightforward jobs, these two model series are complemented by vibrators with fixed eccentric moment. Diesel-hydraulic power packs with modern control and operating systems are available in various output classes to match vibrator size and driving requirements. To ensure a secure connection between pile and vibrator, MLLER supplies a wide range of clamping devices and adapter plates for all applications. For smaller jobs, MLLER offers powerful yet compact vibrators with fixed and variable amplitude for attachment to hydraulic excavators. Leader-mounted vibrators with variable amplitude are specially designed for attachment to telescopic leaders.
MLLER also provides related accessories such as data logging systems, adapter plates and drill drives for preparatory drilling. Their ease of operation, low maintenance requirements and long service life make MLLERvibrators both economic and dependable. ThyssenKrupp GfT Tiefbautechnik GmbH is a competent partner for special vibration technology applications. Our experts in geotechnical engineering, machine construction and control technology can provide support and advice in the development of your projects.
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How MLLER-vibrators work. MLLER-vibrators with fixed eccentric moment (H series) The vibrators are fitted with eccentrics which generate a fixed eccentric moment of 25 or 50 kgm. For continuous use or use in extreme climatic conditions, vibrators can be equipped with a forced lubrication system including oil cooling (H3 series). High-frequency MLLER-vibrators with stepwise variable eccentric moment (HHF series) The vibrators in the HHF series are suitable for a broad range of applications. The eccentric moment can be increased or reduced in steps by adding/removing additional weights, allowing one vibrator to achieve different amplitudes and frequencies. Eccentric moments of up to 190 kgm can be generated. High-frequency MLLER-vibrators with variable eccentric moment (HFV series) When starting these vibrators, the eccentrics are arranged in such as way as to mutually balance out the centrifugal forces they generate and thus prevent any vibration. Once the required frequency has been reached, the eccentrics are turned counter to each other so that the centrifugal forces act in the same direction and generate vibration. This makes it possible to avoid passing through the resonance frequency of the soil (approx. 10 to 25 Hz depending on soil type) during starting and stopping. At present, the eccentric moment of models in this series can be varied between 0 and 62 kgm.
Ground vibration
Ground vibration
Excess vibration
Frequency
Resonance frequencies
Resonance frequencies
Starting phase
Stopping
Centrifugal force kN 5
MS-10/17 HF (B) MS-25 HHF MS-50 HHF MS-100 HHF MS-120 HHF MS-200 HHF 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 30003200 3400 3600 3800 4000
Example: Double pile Weight: 3.0 t Driving depth: 17 m Vibrator selected for mediumdense soil = MS-50 HHF
Vibrator selection The graphic provides help in determining the required centrifugal force or in selecting the right vibrator based on soil conditions, pile weight and driving depth (see above). Mark a point on the left-hand side of the table representing the maximum driving depth, and another point on the right-hand side marking the maximum pile weight. At the point where this line crosses the soil data line for your project, draw a vertical line to the vibrator models. This provides an overview of the units which can be considered for your requirements. To determine the exact model, we can offer competent advice taking account of site-specific, geological and technical requirements.
Speed (frequency) n [rpm] The speed dictates the vibration frequency of the system. The vibrations are transferred via the pile to the surrounding soil, significantly reducing the surface friction between pile and soil. High frequencies counter the unwanted spread of vibrations in the soil.
Transmission of the pile acceleration to the surrounding soil causes the displacement of the particle structure and reduces particle friction and soil resistance. Acceleration is indicated as the ratio of acceleration to gravity: = a g F 10-1 Gdyn
Importent details For high-frequency vibrator applications, the centrifugal forces determined in this way should be 30% higher. Use of additional aids such as flushing pipes or preparatory drilling can significantly increase the driving performance of a vibrator.
F = M 2 n 2 ) 30
The centrifugal force must be high enough to overcome surface friction between pile and soil. Centrifugal force plays a major part in reducing surface friction and provides impact force to overcome tip resistance.
Drive output P [kW] The drive unit must be powerful enough to generate the moment needed to maintain the centrifugal force of the vibrator, even in difficult ground. The drive output should be 2 kW per 10 kN centrifugal force.
Key vibration technology data Choosing the right vibrator for the job mainly depends on pile size, driving depth and soil conditions. The greater the driving depth and the harder or more compact the soil, the higher the centrifugal force and amplitude required. Centrifugal force and amplitude need to be high enough to overcome the surface friction and tip resistance between the pile and the surrounding soil. Key vibrator data in this context are shown in the following descriptions and formulae.
Gdyn = GVIB + Gpile + Gsoil Together with centrifugal force, amplitude is a measure of driving performance. A large stroke and high impact force ensure good driving progress. When driving and extracting in cohesive soils, the elastic connection between pile and soil can only be broken if the amplitude is high enough.
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The vibrators in this series are extremely robust and suitable for driving in loose to medium-dense soils. The stretched base plate in particular is ideal for driving and extracting pipes for in-situ concrete piles. The clamping devices on the base plate can be steplessly adjusted to allow a simple changeover to different pipe diameters on site.
Vibrator
MS-25 H2
MS-25 H3
MS-50 H2
MS-50 H3
Centrifugal force Eccentric moment Speed Frequency Pulling force Weight (dynamic) Weight (total) Amplitude Oil flow Pressure Power consumption Dimensions:
F (max.) M stat n (max.) f (max.) F pull (max.) without clamping device without clamping device without clamping device/pile Q Motor (max.) p (max.) (max.) at vibrator Length L Width B Height H
774 25 1680 28.0 400 1930 3200 25.9 374 350 218 2200 681 1685 260 100 150 (A) 2 x 54
774 25 1680 28.0 400 2550 3600 19.6 374 350 218 2200 777 1745 260 100 150 (A) 2 x 54
1430 50 1615 26.9 500 3340 6300 29.9 719 350 419 2560 696 2035 420 150 200 2 x 90 2 x 100
1430 50 1615 26.9 500 3820 6790 26.2 719 350 419 2560 696 2105 420 150 200 2 x 90 2 x 100
Centrifugal force
F limit
n limit
Rpm
The vibrator can be adapted quickly to different soil conditions by a simple system of adding or removing weights, allowing the eccentric moment to be varied. For example, if high frequency is required for work in loose sand, the additional weights can be removed simply on site to achieve high frequencies with the same centrifugal force.
Vibrator
MS-25 HHF
MS-50 HHF
MS-100 HHF
MS-120 HHF
MS-200 HHF
Centrifugal force Eccentric moment Steps Speed steps Frequency steps Pulling force
F pull (max.)
kN 750 1500 kgm 25 50 kgm 12/15/20/25 24/30/40/50 rpm 2170/2113/1830/1637 2362/2113/1830/1637 Hz 39.3/35.2/30.5/27.3 39.3/35.2/30.5/27.3 kN 280 500 kg kg mm mm l/min bar kW mm mm mm MS-A MS-U MS-U MS-U MS-U 2900 3700 17,2 8.3/10.3/13.8/17.2 298 470 350 350 174 274 1800 660 1885 170* 260 90 100 2 x 54 2 x 70 4500 6100 22,2 10.7/13.3/17.8/22.2 610 964 350 350 356 562 2300 660 2465 420* 660 180 250 2 x 90 2 x 100
2500 3003 100 116 48/60/80/100 80/94/110/116 2160/1920/1670/1500 1850/1700/1570/1536 36/32/27.8/25 30.9/28.3/26.2/25.6 600 1200 7700 10900 26,0 12.5/15.6/20.8/26.0 1045 1286 350 350 610 750 2410 660 3235 660* 840 360 8900 15500 26,1 18.0/21.1/24.7/26.1 989 1150 1534 350 350 350 577 671 895 2360 1140 3425 660* 840* 1050 360
4000 190 (98)/110/150/190 (1800)/1800/1560/1371 30/26/22.9 1200 11750 15500 32,4 16.7/18.7/25.5/32.4 1435 1680 350 350 837 980 2300 1352 3655 840* 1050
Weight (dynamic) without clamping device Weight (total) without clamping device Amplitude without clamping device/pile Amplitude (steps) without clamping device/pile Oil flow Pressure Power consumption Dimensions: Q Motor (max.) p (max.) P (max.) Length L Width B Height H
2 x 150 2 x 180
2 x 180
2 x 250
Centrifugal force
F limit
M stat
> M stat
> M stat
> M stat
n limit n
Rpm
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MLLER-vibrators. HFV series with variable frequency and amplitude and resonance-free starting and stopping.
The need to avoid vibration and noise emissions e.g. on inner-city sites is becoming increasingly important. Our range of state-of-the-art variable vibrators with resonance-free starting and stopping was designed specially for this. These machines deliver exceptional performance while minimizing noise and vibrations. They allow frequency and amplitude to be matched optimally
to the soil conditions. The precision programmable controller enables several functions to be combined and carried out with just one command. The controller can also be set so that frequency does not fall below a preselected level.
Vibrator Centrifugal force Eccentric moment Speed Frequency Pulling force Weight (dynamic) Weight (total) Amplitude Power consumption Oil flow Pressure Dimensions: F (max.) M (variable) n (max.) f (max.) F pull (max.) without clamping device without clamping device without clamping device/pile at vibrator Q Motor (max.) p (max.) Length L Width B Height H kN kgm rpm Hz kN kg kg mm kW l/min bar mm mm mm MS-A...V
MS-10 HFV 610 0 - 10 2358 39.3 180 1700 2300 11.8 147 203 253 348 350 350 1635 732 1530 170* 260 MS-U 72 MS-U 100 2x 2x MS-U 54 MS-U 70
MS-16 HFV 969 0 - 16 2350 39.2 300 2600 3500 12.3 220 294 378 504 350 350 1930 757 1995 260* 420 MS-U 150 A MS-U 150 MS-U 70 MS-U 90
MS-24 HFV 1480 0 - 24 2350 39.2 400 2900 5050 16.6 404 551 693 945 350 350 1920 893 2145 420* 660 MS-U 180
MS-32 HFV 1979 0 - 32 2375 39.6 600 4850 7250 14.2 610 720 1045 1235 350 350 2371 800 2455 660* 840 MS-U 250
MS-48 HFV 2960 0 - 48 2350 39.2 600 6520 9700 15.2 603 823 1034 1410 350 350 2371 1123 2525 660* 840 MS-U 360
735 980 1260 1680 350 350 2371 1123 2525 840* 1050 MS-U 360
MS-U 150
MS-U 250
MS-U 250
F = 100 %
Centrifugal force
F limit
F=0%
n limit n
Rpm
The hydraulic vibrators are powered by power packs, in which a diesel engine-driven hydraulic pumps deliver a flow of pressurized oil to the hydraulic motors on the vibrator. All power packs are silenced and are controlled and constantly monitored during operation by a specially adapted programmable controller. The vibrator is operated via a cable remote control, or optionally by radio remote control. The operating parameters of the vibrator can be monitored via an online connection. Should a problem occur, our experts can analyze the operating parameters and provide immediate initial assistance by phone.
Aggregate Diesel engine Type Exhaust certification EU / EPA Power P (max.) kW Speed n (max.) rpm Pumps: Flow rate Operating pressure Fuel tank Hydraulic tank Dimensions: Length L Width B Height H Weight with oil/without fuel
Q (max.) p (max.)
l/min bar l l mm mm mm kg
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The clamping device provides a vibration-proof connection between piles, beams and pipes and the vibrator. The clamping force (kN) of the clamping device must be at least 1.2 times higher than the centrifugal force (kN). Arrangement of clamping devices As single clamps, double clamps for U- and Z-type sheet piles, I-beams and pipes. Special clamping devices are available for special applications, e.g. for wooden piles, concrete piles, small-diameter pipes. All MLLER-vibrators can be fitted with a variety of adapter plates to allow numerous different clamping device arrangements. Special clamping devices are also available for driving double piles and pipes.
MLLER-safety grippers Available in different sizes, the safety grippers are the ideal solution for quick pile pick-up. They guarantee simple and safe working when uprighting sheet piles and other steel sections.
h d
max. i g a c
Pulling force 30 kN 40 kN 50 kN
Weight 15 kg 24 kg 26 kg
Clamping devices
Type MS-U 12 * 40 * 54 60 * 70 72 90 100 150 180 200 250 360 Clamping force kN 122 370 540 600 700 720 900 1000 1500 1800 2000 2500 3600 Dimensions mm f 223 285 690 350 525 350 525 530 550 592 800 840 950 Weight g 175 200 220 290 220 290 275 320 325 430 410 520 h 730 780 780 780 780 ** 780 1150 ** max. i 15 40 21 40 35 40 35 50 50 80 50 63 80 IPBmin 120 120 180 140 180 140 180 280 320 300 450 450 400 kg 50 190 440 260 615 260 620 680 770 1250 1600 2400 3130
a 225 508 650 600 770 600 770 751 890 954 1010 1340 1255
c 195 260 270 320 340 320 340 345 340 390 380 400 460
d 195 475 515 480 580 480 580 610 640 745 880 870 1180
* only for excavator-mounted vibrators / ** Option: without clamping bar, can be supplied bolted directly to the vibrator
MLLER-excavator-mounted vibrators
Type Centrifugal force max. kN Eccentric Fremoment quency max. max. kgm Hz Pulling force max. kN Push down max. kN Power at vibrator max. kW Oil flow l/min Amplitude mm Weight Weight dynamic total (incl. clamp) (incl. clamp) (incl. clamp) mm kg kg Height
MS-1 HFB MS-2 HFB MS-3 HFB MS-4 HFB MS-6 HFB MS-7 HFB MS-10 HFB MS-17 HFB MS-5 HFBV3 MS-8 HFBV3 MS-4 HFBS MS-6 HFBS MS-7 HFBS
90 245 296 374 464 604 600 604 400 585 378 464 604
0,7 2,2 3,0 4,2 6,5 7,0 10,0 17,0 0-5 0-8 4,2 6,5 7,0
56,0 53,1 50,0 47,5 52,5 46,7 39,0 30,0 45,0 43,0 47,5 42,5 46,7
34 60 60 120 120 150 140 140 120 150 120 120 150
102 105 120 171 204 224 257 270 162 283 171 204 224
6,1 7,7 10,3 8,9 13,7 14,7 12,0 19,8 8,8 12,4 7,7 11,6 12,4
761 1024 1024 1137 1137 1150 1530 1530 1303 1583 1250 1250 1250
350 815 830 1230 1240 1300 2410 2468 1580 1815 1360 1370 1380
230 570 585 940 950 950 1660 1713 1130 1295 1110 1120 1130
Selection, mounting and handling The vibrator is attached to the stick of the excavator and powered by the excavators hydraulic system. A stick tilting section is needed to operate and control the vibrator. The special design of the push head allows additional static force to be applied to the pile by the excavator boom, which can greatly enhance driving performance. The choice of vibrator depends on the available engine power, oil flow rate and pressure as well as the soil conditions.
Advantages Low height of excavator-mounted vibrators Automatic clamping device High pulling force Rotatable clamping devices All vibrators fitted with a safety circuit
MLLER-leader-mounted vibrators
Type Centrifugal Eccentric force moment max. kN max. kgm 0-8 0-10 0-14 0-16 0-20 Speed max. pmr 2352 2340 2370 2376 2340 Frequency max. Hz 39,2 39,0 39,5 39,6 39,0 Pulling Weight Pressure force total max. kN (incl. clamp) kg max. bar 120 180 180 180 180 2000 2000 3450 3650 3840 360 360 350 350 350 Height mm 1870 1870 1710 1710 1710 Waist mm 450 450 455 455 455 Clamp MS-U 72 72(125D) 125D 125D 150
MS - 8 HFMV 500 MS-10 HFMV 600 MS-14 HFMV 832 MS-16 HFMV 969 MS-20 HFMV 1200
Using MLLER-leader-mounted vibrators MLLER-leader-mounted vibrators in combination with proven variable moment control are ideal for driving and extracting steel sections such as pipes, sheet piles and beams and for use in foundation work such as the construction of compacted gravel or sand piles etc. They are slim enough to drive and extract small single piles and to work in tight conditions. Resonance-free starting and stopping protects both the surrounding area and the carrier from damaging vibrations and emissions.
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Low-noise, vibration-free drill drives from MLLER are available in three different mounting versions. They can be mounted on the guide slide of a leader, on the stick of an excavator or in the clamping device of a vibrator. They allow pressure-relief and preparatory drilling to be carried out quickly, particularly in very dense soil.
L L
D D D SW SW SW
RHA 102 RHA 142 RHA 105 RHA 145 RHA 106 RHA 146 Torque max. kNm Oil flow rate on drill unit max. l/min Oil pressure on drill unit max. bar Rotary speed max. rpm Drilling tool connection SW mm Length L mm Diameter D mm Diameter of continuous flight auger up to mm Weight of drill unit approx. kg Weight of auger guide approx. kg Weight of transportation frame approx. kg 10 260 300 125 70 830 335 300 280 100 40 14 350 300 115 70 880 390 450 360 110 40
RHA 281
RHA 103
RHA 143
RHA 203
RHA 283
RHA 403
Logging parameters such as frequency, pressure, depth etc. is of great importance in civil and special engineering work. These data are frequently the only way of identifying obstacles or variances from the expected structure of the subsoil. Various sensors for measuring depth, flow rate, vibrations etc. can be connected directly to a data logger and the registered data printed out as a record of vibration work.
Vibration sensor
14 15
Vibration and tamping system: A wide variety of systems and processes can be used to improve the subsoil for construction work. One simple and particularly effective method is soil improvement through self-compaction or the addition of suitable materials. The MLLER vibration and tamping system is ideal for this. Depending on the material added, it can be used to produce vibrated concrete piles, compacted gravel piles and stone/mortar piles. The material runs from the hopper via the inner pipe to the outer pipe, and from there into the cavity in the soil created by vibration driving. This method produces homogeneous stone or concrete piles with a very high level of compaction. Ground improvements can also be made in loose, non-cohesive soils by vibration (self compaction).
MRC system: Loose to medium-dense gravel and sand can be effectively compacted by displacement to improve load-bearing capacity. Non-cohesive ground such as this can be compacted using the MRC (Mller Resonance Compaction) process. This process is based on transmitting the vibrations generated by the MLLER-vibrator to the ground via a compacting pile, thus setting up resonance vibrations in the soil. All important compaction readings as well as performance data are registered and directly displayed to the machine operator. In this way, the variablefrequency vibrator can be adjusted to match the ground conditions.
DYSTAFIT : Expensive ground improvement measures and maintenance costs for rail track structures can be reduced if the long-term dynamic stability of their subsoil/substructures can be verified. To provide this in-situ verification, ARCADIS Trischler und Partner in collaboration with ThyssenKrupp GfT Tiefbautechnik, Alsfeld developed the patented mobile test unit DYSTAFIT on behalf of PBDE, Leipzig. Using the MLLER-vibrator, the subsoil/substructure can be subjected to dynamic loads in a frequency range between 5 and 45 Hz. This test set-up allows stability levels to be measured in any ground which is susceptible to settling, sinking or shifting. DYSTAFIT can also be used to test the effects of increased speeds on lines modified for high-speed trains. In practical testing, up to 3 million load cycles were performed for each test cross section in continuous operation.
Thin diaphragm wall: Thin diaphragm walls are an economical way of providing vertical sealing in hydraulic and foundation engineering. This method is mainly used in dikes, dams, landfills and to contain subsoil contamination. To produce a thin diaphragm wall, a steel beam with a wider bottom end is driven into the ground to be sealed using a MLLER-vibrator. The steel beam is equipped with flushing or slurry pipes. In this way, the gap created and part of the surrounding soil is filled/mixed with slurry. A roughly 50 cm deep flow trench in the narrow wall axis takes up excess slurry and compensates for slurry losses. By vibration driving the steel beam with an overlap, a narrow sealing element is created. Depending on the soil quality, wall depths of up to 30 meters are possible.
slab track e.g. Rheda vibrator e.g. MS-24 HF VAR load plate steel plate
insulator clamp
ThyssenKrupp GfT Bautechnik GmbH P. O. Box 10 22 53, 45022 Essen, Germany Altendorfer Str. 120, 45143 Essen, Germany Phone: +49 201 188-2313 Fax: +49 201 188-2333 bautechnik@thyssenkrupp.com www.tkgftbautechnik.com Export Altendorfer Str. 120, 45143 Essen, Germany Phone: +49 201 188-3758 Fax: +49 201 188-3974 export-bautechnik@thyssenkrupp.com Eastern Europe Altendorfer Str. 120, 45143 Essen, Germany Phone: +49 201 188-3769 Fax: +49 201 188-3730 osteuropa-bautechnik@thyssenkrupp.com Represented by:
ThyssenKrupp GfT Bautechnik GmbH P. O. Box 10 22 53, 45022 Essen, Germany Altendorfer Str. 120, 45143 Essen, Germany Phone: +49 201 188-2313 Fax: +49 201 188-2333 bautechnik@thyssenkrupp.com www.tkgftbautechnik.com Export Altendorfer Str. 120, 45143 Essen, Germany Phone: +49 201 188-3758 Fax: +49 201 188-3974 export-bautechnik@thyssenkrupp.com Eastern Europe Altendorfer Str. 120, 45143 Essen, Germany Phone: +49 201 188-3769 Fax: +49 201 188-3730 osteuropa-bautechnik@thyssenkrupp.com Represented by:
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