Copper miningPM shotcrete machines

Truck-mounted concrete pumpsThe full range

Originals are betterCopies aren‘t worth it

In the land of the elephantPutzmeister in India

Visit us in Munich, April 19 – 25, 2010

in Hall B6, stand 100 / 400

Customer magazine by Putzmeister Group 78

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Titel

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Imprint

Publisher: Putzmeister Concrete Pumps GmbH, Max-Eyth-Straße 10, 72631 Aichtal / Germany Editorial department: Volker WehnerPutzmeister Concrete Pumps GmbH

Layout/DTP: GleisNeun GmbH, Gerbergasse 16, 97877 Wertheim / Germany Print: Offizin Scheufele GmbH + Co. KG, Tränkestraße 17,70597 Stuttgart / Germany

Welcome to Bauma, welcome to Putzmeister in hall B6.

The last two years have been marked by dramatic changes in the global economy and almost every company has been affected by this. And in many meetings, we have learnt from you, our customers, how you are adjusting to this in your business.

We have based our trade fair appearance on this: with new machines and plant solu-tions, which can also open up opportuni-ties in the difficult market environment. These include the M 49-5 truck-mounted concrete pump on 4 axles, a new shotcrete machine for small tunnel diameters and the Telebelt TBS 130, which can be a new business approach for service providers, as a semi-trailer. Consistent further deve-lopment and staggered services aim to optimise applications and reduce your ope-rating costs.

India is the partner country of this year‘s Bauma. That‘s why this issue includes a brief insight into the activities of our Indian subsidiary, which has made a good name for itself there in just a short time.

Our trade fair stand for 2010, as always, is in hall B6. This should give you an outward sign that we, the new company manage-ment, stand for continuity in accordance with our motto “Serve, Improve, Create value”.

We look forward to your visit.

Norbert ScheuchManaging DirectorPutzmeister Holding GmbH (Chairman) and Putzmeister Concrete Pumps GmbH (CEO)

Dr. Robert AbelManaging DirectorPutzmeister Concrete Pumps GmbH (CCO)

Title picture: The Colorado River Bridge on the Hoover Dam crosses the river at a height of approx. 294m.

The main contractor for the project was an Obyashi/PSM Joint Venture. The sub-con-tractor for concrete pumping was Quinn Concrete Pumping. From the outset, Putz-meister was involved in this project in an advisory capacity. In the end, a wide range of PM machines was used: the stationary concrete pumps BSA 2107 HP-E and BSA 2109 H-E, the stationary booms MX 32/36 Z and MX 36/40 Z, and the truck-mounted concrete pumps M 42 and M 58.

Due to the heat and to avoid blockages, pumping was carried out predominantly at night.

Foreword

Truck-mounted concrete pumps

New solutions in practice and the full range at Bauma

M 49-5 – With 4 axles in the fast lane

Technology

Important PUMI functions significantly improved

Telebelt –From specialist to attractive allrounder

Increased profitability for the prefabricated parts industry

The P 13 piston pump – the “offroad plastering machine”

Bauma partner country India

“Our core competences remain product, quality and service”

Not just for India – robust and cost-effective trailer concrete pump

Mining and tunneling

New high-performance pump for mining tailings and fly ash

The new SPM 4207 – concrete spraying specially for small tunnel cross-sections

Services

Fleet management with the i-DAISY international web application

Economic concrete placement beyond the reach of truck-mounted concrete pumps

Beware of cheap parts and dumping offers!

Putzmeister used machines – first class from second hand

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Foreword

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Truck-mounted concrete pumps

Truck-mounted concrete pumps – new solutions in practice and the full rangeAt the trade fair stand, Putzmeister will exhibit many models, from the smallest to the biggest truck-mounted concrete pump. The machines, with vertical boom reaches of approximately 20 to 70 m are, as shown in the following overview, very specifical-

ly tailored to the needs or requirements of individual countries and applications.

With various models, Putzmeister shows its wide range of innovative technology such as Follow-me, EBC (Ergonic Boom

Control) or the patented TRDV variable position support system. There is also practice-oriented equipment and options, such as the Sanima kit, radio remote con-trol with display, solutions for the exten-sion of end hoses, etc. n

Not exhibited at Bauma in Munich: The BSS 46-5 truck-mounted concrete pump exhibited for the first time at the Indian Excon last November.

This large boom trailer is special-ly tailored to the specific require-ments of the Indian market. Above all, the Indian conditions for appro-val for road use had to be met. Since 4-axle vehicles are limited to a maxi-mum gross weight of 31 tons, 46 m vertical reaches are not so feasible.

The answer is a 3-axle tractor unit with 3-axle trailer, which is significantly under the permissible gross weight of 44 tons.

The large boom for IndiaAnother important argument, in addi-tion to the enormous reach with the flexible 5-arm boom, is the efficient independent power unit. In addition, it is possible to pump without a trac-tor unit. This means the tractor unit is free to be used for other tasks. n

BSS 46-5 – the 5-arm large boom specially designed for

the Indian market

M 42-4 in use in Emirate Scharjah (UAE)

Truck-mounted concrete pumps

M 20-4 Ideal for halls, under bridges, etc. with 3.9 m minimum unfolding and wor-king height. It also has the smallest support area and is extremely mano-euvrable on the road.

M 36-4The bestseller in the 30 m class: Ver-satile thanks to the flexible Z fold system and small support area..

Bauma tip: At the trade fair, we will be performing a live demonstration of the latest version of the Follow Me technology on the M 36-4.

M 49-5Maximum reach and optimal price-performance ratio: Available either on 4 or 5 axles. On the Chinese market, a special version of the M 49-5 is availa-ble (see next page).

M 58-5The large boom on 5 axles with space-saving, variable position TRDV sup-port. This means the machine doesn‘t take up any more space than is abso-lutely necessary.

M 70-5The world‘s longest 5-arm boom in actual construction site use. Full uti-

lisation of the reach without limiting pump torque. The innovative IRS support techno-

logy ensures minimum space requirements.

M 42-5Allrounder on 4 axles with flexible 5-arm RZ fold system.

Practical detail: The container on the support leg gives additional storage space.

Maximum reach of 20 to 70 m

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The request for maximum reach on 4 axles first came from the Chinese market. Putz-meister exhibited its new M 49-5 truck-mounted concrete pump for the first time at the last Bauma Shanghai. The innovati-on was an immediate success there.

This was due to the right balance between reaching the permissible gross weight for the 4-axle chassis (HINO) established on the market there and the minimum sup-port area with a flexible 5-arm boom. In addition, the price for the M 49-5 should be significantly lower than the M 52-5 with the highly flexible, variable position TRDV support. These advantages will be presen-ted by Putzmeister in Europe for the first time at the Bauma fair.

The gross weight of this machine on 4 axles is approx. 40 tons. It is therefore of interest wherever a large boom is required on a low-priced chassis with a maximum reach of 50 m. The RZ fold system offers crucial advantages in certain applica-tion situations in high-rise construction (see box). n

M 49-5 – with 4 axles in the fast lane

The range of Putzmeister collector‘s models is certainly not as wide as the range of actual 1:1 models. But in terms of quality and attention to detail, Putzmeister is uncompromi-sing here too. All available models are “Made in Germany“ and come from the famous model maker Conrad.

At this year‘s Bauma, you can purchase these concrete pumps, PUMIs and mortar machines in the Putzmeister advertising gift shop at trade fair pri-ces. Moreover, they are available to collectors via the Putzmeister web shop the whole year through. n

You can find our shop at:www.mycybershop.de/shopPM

The additional 5th arm and its hinge increase flexibility, possible uses and net reach of a truck-mounted concrete pump (top). Due to a lack of mano-euvrability, a 4-arm boom is much more difficult to slip into buildings. It may have to give up on attaining its net reach, depending on how great the distance is.

Practical training is worth itPutzmeister offers its customers a wide ran-ge of possibilities for training and further training. In theory courses, with learning modules developed in-house by Putzmei-ster, and in practical courses, users of Putz-meister machines can learn the best way to use their PM products. n

Please contact us at: www.pm-akademie.de

The worldwide local training courses ensure increased competence and efficiency.

With our qualified personnel, you can learn in practical situations, thereby avoiding later operating errors. This increases safety for man and machine.

Improper handling can be prevented through competent training.

Training significantly reduces mainte-nance requirements and costs.

Concrete pump models for collectors

Here, the 5-arm boom of the M 49-5 shows an enormous horizontal reach.

ServicesTruck-mounted concrete pumps

Beside numerous models true to the original like the Pumi you will find our exclusive anniversary model of the 1972 truck-mounted concrete pump in our webshop.

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Internet

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Order data/GPS data

Scheduling diagram –order progressautomatically

Delivery noteadministration –semi-automatic

Display ofgeographical location

Time recording

GPS location

Order processing

Communication /radio datatransmission GPRS (TCP/IP)

Central internet server

Telephone reception of customer order

Entry of customer order

With i-DAISY, Putzmeister offers simpli-fied, Internet-based scheduling of the machine fleet with machine location, especially for customers abroad.

The connection between the vehicles and the concrete pump headquarters is esta-blished via GPRS (General Packet Radio Service). Access via the Internet means the system is available internationally. To this end, certain technical, personnel and lin-guistic conditions are required on site.

With i-DAISY, the company‘s entire vehi-cle fleet including truck mixers, silo trains, etc. can be scheduled. Likewise, an econo-mically viable cooperation is possible for operators with widespread sites and part-ners. These are the experiences of the Reno Pumbeton AG concrete pumping service in Maienfeld, Switzerland, for example.

Reno Pumpbeton AG is a joint venture of 4 local concrete plants. They joined forces in order to offer their customers a pum-ping service. Each pump is stationed at a different site and pump scheduling is performed locally at the respective con-crete plants. Mr Tobler (technical mana-ger) reports that in the past this meant that several calls were often required bet-

Fleet management with the i-DAISY international web application

ween the plants and the customer in order to reserve a site use. This system was very time-consuming and inefficient for the customer and for the schedulers. With the introduction of i-DAISY at the end of 2007, the situation improved instantly.

Complete overview for schedulers. At any time.

Although scheduling is still decentralised, each scheduler has a full overview of the availability of the concrete pumps and the status of the current orders. He can there-fore book a site use for a customer or, if the desired pump type is not available, offer alternatives immediately.

This clear plus point in service is rated highly by the customers and the schedu-lers, after initial scepticism, can no lon-ger imagine working without i-DAISY. In the opinion of Reno Pumpbeton AG, expe-rience with i-DAISY has shown the follow-ing advantages: Easy operation, minimum training effort, low investment costs (PC with Internet connection), improved custo-mer service and increased efficiency, opti-mal planability and utilisation of the fleet.

A further advantage is that i-DAISY incre-ases transparency, resulting in a more visible site status of the vehicle, time recor-

ding by clocking in and off in the vehicle, GPS localisation of the vehicle and display of the vehicle and site of use on the map.

In addition, fully automatic construction site processing is possible with i-DAISY. In other words, the construction site sta-tus, the arrival and departure from the construction site, as well as the start and end of pumping operations are determined and transmitted by the vehicle equipment, BCL on-board computer, without interven-tion by the driver.

i-DAISY can also be combined with the red-uced and more cost-effective functions of the standalone module i-GOT-U. There, as in i-DAISY, the current vehicle positions and, retrospectively, the routes driven, are displayed. In addition, the system can send e-mails or text messages to defined addressees, for example if a vehicle leaves a geographically defined region or inter-ventions are made on the BCT on-board computer. n

Fleet management system

Seven years ago, we introduced the Ergonic control for the PUMI. This tried and tested technology allows us to reali-se further application-oriented functions easily. Some of these are new at BAUMA. We spoke with Frank Riderer, the head of the PUMI Business Sector, on this subject.

PM: What are the innovations in the im- proved PUMI? FR: We have several interesting new op-tions. These include, for example, a radio remote control with display.

PM: This will primarily help the machine operator. Are there other new functions to help the operator?FR: Yes, with the software controlled Ergo-nic, it is possible to realise even complex processes, such as an automatic draining function. This is difficult or impossible to accomplish with purely hydraulic con-trols.

PM: What does “automatic draining func-tion” mean?FR: With this patent-pending function, the speed of the mixer is adapted to the deli-very rate of the pump. That is, with a low delivery rate, the mixer also turns slowly. Jerky start-up and braking of the mixer, as was the case before, is therefore resolved.

Important PUMI functions significantly improved

PM: You are exhibiting a mixer cleaning function. What‘s behind this?FR: If this function is activated during pumping, for example, the mixer drum automatically rotates briefly to the right and then to the left, without any interven-tion by the operator. This causes the water in the drum to slosh to and fro so that any concrete stuck in the mixing spirals near the outlet can be continuously rinsed and washed away with very little water.

PM: What option do you consider to be parti-cularly interesting?FR: The request by a Swiss customer, who wants to add water to the mixer drum metered via the radio remote control.

PM: What is the advantage of this?FR: Often, after starting to pump, the placement team complains that the con-crete is too stiff. The machine operator must then go from the site of concrete placement to the machine to add water to the concrete and then mix it through again. In future, this will be possible directly from the radio remote control.

PM: Is it actually permissible to add water to the concrete mixer?FR: It is permissible to add water to the concrete if it is scheduled, there is a mete-ring device and the added water volume is noted on the delivery note. n

The Ergonic radio remote control with display

Die PUMI 31.89 S in operation

Frank RidererBusiness Sector Manager

Email:RidererF@pmw.de

Pumi

The PUMI 31.89 S exhibited at the trade fair stand is also available in a version with a vertical reach of nearly 28 m.

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Economical concrete conveying beyond the reach of truck-mounted concrete pumps

Concrete Project Division (CPD) project consultationConcrete Project Division (CPD) project consultation

Concrete pressure < 130 bar

High, deep and long-distance placement

• Economical solution for common applications with stationary concrete pumps • Low material weight, short assembly times, easy handling

Just like in sports, Putzmeister had to work hard for the many, worldwide pump records in its history in concrete high-rise and long-distance placement.

Essentially, these records were achie-ved by the right solutions to engineering requests or, in other words, the success-ful implementation of customer require-ments.

This decade-long development of concrete placement concepts is today the foundation of machine technology and, above all, the knowledge to which the Putzmeister engi-neers from the Concrete Project Division (CPD) refer in their engineering services. The field of application here ranges from high-rise, power plant, water, dam and bridge construction to tunnelling, long-distance concrete placement and excava-tion.

The CPD contacts will be at Bauma, in hall 6 or outside, ready to answer your que-stions or discuss your individual Projects. Wie present you the following machines and aspects of stationary concrete place-ment technology at Bauma:

• Concrete placement climbing system RS 850 with the new boom MX 30(33)-3• Stationary pumps from various service classes in electric and diesel versions• System parts from the Putzmeister concrete delivery line, coupling and gate valve systems, designed for concrete pressures of 85 bar to over 200 bar.

The Putzmeister Concrete Project Divisi-on (CPD) is your partner for:

• Demanding concrete delivery tasks in construction engineering• Consultation in the fields of concreting logistics, concrete technology with the focus on „pumpability of concretes“ and concreting processes

The aim: Increased profitability through timely planning of the correct machine technology and the right concrete place-ment processes. n

Solutions “off the shelf” do not meet all requirements. In special projects in particular, intelligent and economic individual concepts are required.

Concrete pressure > 200 bar

Extremely high and long-distance concrete placement

• Very good stability in the event of load shifting during concrete pump switch-over at very high pump pressures

• Very good line stability and assembly High wear-resistance and long service life

Concrete pressure 130 – 200 bar

High-rise construction up to approx. 450 m, far and deep placement

• Economical solution for large outputs at high pressures • Very good line stability and flexibility • High wear-resistance and long service life

Special cases require individual solutions: For example, the “Dubai gate valve”, which was responsible for enabling the record-breaking delivery heights of over 600 metres during the construction of the Burj Khalifa.

Concrete work on Block 3 of the Finnish KKW Olkiluoto

Concreting of the huge cavern of the Austrian pump accumulator power plant KOPS II

Super high-pressure pumps BSA 14,000 SMPD in use for high-rise pumping at the Burj Khalifa (formerly Burj Dubai).

Sample applications of Putzmeister concrete delivery line systems and concrete gate valve systems

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The Putzmeister Telebelt (Telescopic Belt Conveyor) is a versatile construc-tion machine for placing concrete and a range of other materials up to a diame-ter of 300 mm. The constant pulsation and pressure-free material transport on the belt allows for high placement (up to 450 m 3/h) with low operating costs.

The world‘s biggest population of Telebelt machines is in the USA. There, the Telebelt is used by service providers as an addition to the truck-mounted concrete pump and places not only concrete, but also hard-core, gravel, sand and other materials on construction sites.

Outside the USA, the Telebelt has previ-ously been used predominantly in dam construction. The reason for this is its strength in delivering standard concretes and non-pumpable concretes, such as coar-se concrete, earth-moist concrete or roller compacted concrete. The Telebelt is also excellently suited to special placement

From specialist to attractive allrounder

Autocor is the name Putzmeister gives to systems for the prefabricated parts industry, in which concrete pumps and placement systems are used to place the concrete particularly efficiently and economically in the formworks.

When identifying a solution, for example, the elimination of bottlenecks, the reduc-tion in maintenance times or less follow-up work due to improved surface quality all play a major role. And depending on the annual capacity, end product, availa-ble hall, investment framework, etc. custo-mer-specific answers have to be developed using modular components. Previously, such systems were predominantly used for the production of prestressed concrete towers for wind energy generation, noise protection walls, prestressed concrete pipe, manholes, bridge elements or 2-dimensio-nal structural concrete components.

To represent this pumping technolo-gy, Putzmeister is exhibiting the rotor pump Autocor BQ 06 at Bauma.

This is just as suitable for a stationary installation as for mobile jobs, for which it is transported from hall to hall to the form-works. As another alternative, the machine can be set up on a carrier frame and the-reby used flexibly in different production halls (see photo).

The BQ 06 fills formwork with concrete quickly and economically. At the same time, there is little concrete residue and cleaning is quick and easy. The Bauma machine shows an attached crane, as spe-cial equipment, with which the delivery line can be easily guided. Other advan-tages of the rotor system: Only one indi-vidual, quick-change wear part and low noise emissions.

For prefabricated parts plants, Putzmeister offers not only machines and equipment, but also competent advice for the operator, so that the system can meet his individual requirements. n

More profitability for the prefabricated parts industry

tasks in gardening and landscaping. The-re, materials like sand, earth and mulch can be conveyed.

With the new semi-trailer version TBS 130, it was possible to change the fields of use world-wide quickly from specialist to all-rounder. The semi-trailer now enables ope-ration of a wide range of tractor units as a Telebelt with just minimal adaptati-on effort. The country-specific approval for road use must be checked, however, a special chassis is no longer required in Europe. n

• ideal for prefabricated concrete parts plants which produce medium or large structural prefabricated parts and use pumpable normal concrete or self-com- pressing concrete• increases the production volume by up to 60% • high quality of parts thanks to continuous concrete placement• cleaner process thanks to closed system• no expensive and time-consuming lining of the formwork thanks to flexible boom• formwork can be filled from top or bottom• separation of crane operation and concreting process

Autocor® benefits at a glance:

The tried and tested Putzmeister Telebelt will in future also be available in a new version as a semi-trailer. This will turn the material transport specialist into an unbeatably versatile multi-talent.

What does this mean for the opera-tor or investor?

• significantly lower investment• almost every make can be used as the tractor unit, even a used machine or a machine from an existing fleet• onward sale is subject to hardly any restrictions in terms of appro- val for road use and the exhaust gas standard of the chassis. This makes financing easier.• lower fuel consumption through the use of the independent power unit belonging to the semi-trailer• significantly lower wear costs per m3 than with truck-mounted concrete pumps

The Telebelt is therefore worth it not only for the high placement volumes

of large projects. This is reason enough to see a familiar subject

in a new light.

This application case shows the filling of large structural parts. The Autocor BQ 06, secured to a carrier frame, moves along the formwork.

Solutions for the prefabricated part industryTelebelt

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PutzmeisterGoa, India

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Here, the person conducting the ceremo-ny, knocks the hard, dry coconut shell on a hard surface until a crack appears and the shell breaks. The sweet coconut milk leaks out and the drops are sprinkled over the venerated object.

The nut is then broken up completely. The 1 to 2 cm thick flesh is peeled out, cut into cubes and distributed among the people taking part in the ceremony as a “Prasa-dam”. Indians understand “Prasadam” to mean holy food, which is first offered to god and then to the bystanders.

This ritual has meanwhile been adopted by nearly all religious communities in India, and is celebrated today when valuable objects are obtained or before the start of any new project. For example, for the first use of a new vehicle, the laying of the foun-dation stone of a new building or the dedi-cation of a bridge, etc.

Of course, at Putzmeister too in India, the delivery of a new truck-mounted concrete pump is celebrated with a “breaking the coconut” ritual.

Extracts from an interview with Mr. M. Schmid-Lindenmayer on the success-ful Putzmeister presence on the India subcontinent.

PM: For around 3 years, Putzmeister has been present on the Indian market with its own plant. What were the reasons for this?SL: We have invested in our own team and production here in India because we are convinced of the big future for this market and wanted to be able to meet demand for marketable products quickly and more ef-ficiently.

PM: Have you as OEM now got a different strategy?SL: Our strategy rests on two pillars. On the one hand, we want to develop products that the market really needs in a short time and bring them onto the market. And on the other hand, we are increasingly expan-ding our service network. This is a criti-cal success factor in this business, which Putzmeister is pursuing worldwide.

PM: How far have you come in this short time?SL: In our modern plant in Goa, with an area of 100,000 m2, we now produce 13 machine types for the Indian market with 250 employees. These are the stationa-ry pumps BSA 1404, 1407, the Moli 1404, Moli 1407 in diesel and electric versions and the truck-mounted concrete pump mo-dels BSF 32.09, BSF 36.07/09, BSF 42.09 and BSS 46.14.

Our BSA 1404 HD, launched last Septem-ber, is now our most popular trailer con-crete pump in India. At the Excon trade fair in November 2009, we were the first to exhibit a homologated M 42 and a M 46 in semi-trailer version - marketable with the Indian truck. These are machines that surprised everyone and which are ideal as a large boom for airports, flyovers, liquid gas tanks, cooling towers and other types of large construction projects.

PM: And to what extent have you built up your service organisation so far?SL: We now already have 13 bases, distri-buted throughout the country, such as in Delhi, Mumbai, Goa, Bangalore and Chen-nai, to name but a few. In addition, we have

of course also invested predominantly in the qualification of our people in sales and service.

PM: How has this expansion been possible in such a short time?SL: There are several reasons. One of the-se is our Indian employees who are willing to learn. They have learnt very quickly with the help of experts from Germany. In addition, their training was very practical: in the after-sales service, during training and in the consultation and implementa-tion of concrete placement in construction projects.

PM: Are there examples of this?SL: Our pumps have been used in very many projects, such as the construction of the underground railway in Delhi, the sports complexes of the Commonwealth Games, many steel and power plants, etc. The most famous projects include Ruby Mill (high-rise in Mumbai), the biggest re-finery in the world by ESSAR and Reliance in Jamnagar as well as the airports in Delhi and Mumbai, which were realised by L&T, India‘s biggest construction firm.

PM: Finally, a completely different question: What are you expecting from Bauma 2010?SL: First, we‘re excited that India is the partner country for this year‘s Bauma. We hope that many customers will visit us at this worldwide trade fair for construction

machinery, that we will be able to make new contacts and that they will ultimately take away a positive impression of the ca-pability of the Putzmeister Group. n

Vascon Engineers Limited, based in Mumbai, is a distinguished Indian con-struction firm with revenue of more than EUR 100 million. It focuses on con-struction projects in the fields of infra-structure, real estate and hotels. Vascon Engineers Ltd. has more than 20 years experience in the planning, develop-ment, construction and administration of a wide range of projects throughout India and has already received many awards from the Builders Association of India (BAI).

For its construction projects, Vascon relies on state-of-the-art construction machinery. This includes 6 BSA 1407 D

“Our core competences remain product, quality and service”

This usually takes place in conjunction with a “pooja” ceremony, during which attention is drawn to new things, thanks are expressed to the Almighty and the bles-sing of the divinities is solicited. n

During the ritual, a coconut is broken until its milk leaks out.

Vishvakarma – “God of the machines”

The modern Putzmeister plant in Goa, with an area of 100,000 m2, produces for the Indian market.

In the “pooja” ceremony, thanks are given for the new object and a bles-sing is sought.

Putzmeister distributors and Service are to be found all over India by now.

stationary pumps. A very prestigious refe-rence is the 190 m tall „Ruby Mill“ office complex project in Mumbai (the current height of construction is 160 m). This cons-truction project is a classic example of how mechanisation improves construction or cycle times and safety standards. For con-crete placement, two M 32 stationary booms and two BSA 1408 HD concrete pumps by Putzmeister, which are more efficient than the BSA 1407, are used.

Mr. Manoj Kallur, Vice President Projects of Vascon Engineers Ltd. says: “We have al-ready been collaborating with Putzmeister for a long time and have had excellent ex-periences. The Putzmeister team provides

us with excellent technical support and helps us to use the machines optimally.

The extraordinary good service provisi-on is a big strength. The excellent boom merits particular mention. It has signi-ficantly simplified an important process and saved us a significant amount of time and effort in concreting.” n

Foreign visitors who are not familiar with the traditions of the Indian subcontinent are always amazed at certain ceremonies and rituals in India. They are usually of a religious origin. A very common tradition, for example, is the centuries-old ritual of „breaking the coconut“.

Vishvakarma is the Hindu god of han-dicraft. According to Indian myth, he not only constructed the cities and palaces of the gods, but also the uni-verse itself. He is worshipped by all tradesmen, engineers and architects on the sub-continent. n

Best experiences

Bauma partner country India

Michael Schmid-Lindenmayer Managing Director, Putzmeister Concrete Machines Pvt. Ltd. in Goa, India

The Blessing Ritual: Breaking the coconut

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The BSA 1004 HD was originally develo-ped for the Indian market. It was to be particularly robust, easy to use and, abo-ve all, cheap to purchase and operate.

And to enable it to be towed from one construction site to the next on the at times very poor roads, the extremely compact machine was equipped with a reinforced chassis and leaf sprung running gear. Add to this a modified trailer hitch, which is also suitable for tractor towing.

The design of the concrete pump unit took into account that, in some emerging mar-kets, concrete is often pumped relatively dry, with a low cement content, unbalan-ced grading curve and aggregate consi-sting exclusively of broken material.

The specialist for site-made mix

The machine was designed to enable even mixed concrete to be pumped reliably on the construction site. To reduce wear, Putz-meister India has retained hard-chromed delivery cylinders as well as particularly wear-resistant spare parts in the concrete area. This concrete pump is recommended for outputs of 40m3/h and delivery heights of up to approx. 100 m.

The BSA 1004 HD has no CE mark and is therefore not intended for sale or operation in European countries as yet. As a robust and compact machine, and with its excel-lent price-performance ratio, it is especial-ly suitable for use in Asia and Africa. n

Not only for India – robust and cost-effective trailer concrete pump

* Values indicate piston side; ** corresponds to the BSA1404 in India

Basic data BSA 1004 HD**

Length 5,677 mm

Width 1,740 mm

Height 2,080 mm

Weight 3,500 kg

Theor. delivery rate 39 / 26* m3/h

Delivery pressure 70 /105* bar

Diameter delivery cylinder 180 mm

Delivery cylinder stroke 1,000 mm

Strokes / minute 26 / 17*

Engine power 49 kW

Hopper volume aprox. 600 L

Filling heigth 1,300 mm

Transfer tube S 2018 PN

Flap straight 150 mm

Control System VHS

The BSA 1004 HD in India corresponds to the BSA 1404.

Working elephants are not uncommon in India. No wonder then, that a Putzmeister machine feels at home here.

Bauma partner country India

At the silver mine in San Bartolomé (Bolivia), two HSP 25100 pumps convey the residue of washed-out sludge into a dumping ground.

Putzmeister Solid Pumps GmbH presents a particularly high-pressure resistant and expandable high-density solids pump for material transport underground: the HSP 25100 SP. This pump system is of parti-cular interest for gold, diamond and zinc/lead mines which need to stabilise their pitheads, backfill demineralised cham-bers economically or pump fine-grained excavated material out of the processing plant.

The HSP 25100 SP is a large-volume pump with two individually-controlled delive-ry pistons. PSP specifically designed the pump to convey mining tailings and to pump fly ash over great distances. In order to achieve as constant a delivery as possi-ble without pressure peaks, Putzmeister can, on request, equip these mining pumps with the PCF control (PCF: Pressure Con-stant Flow).

The HSP pump head is modular in design. This makes a noticeable contribution to reducing operating costs. The replacement of worn parts now only involves repla-

New high-performance pump for mining tailings and fly ash

cing the actual worn-out components and no longer encompasses the entire pump head.

Lowering operating costs with the right service

Putzmeister Solid Pumps GmbH focuses strongly on the subject of reducing opera-ting costs. There are numerous different ways of achieving this, depending on the country, operational requirements and cost structure. For this purpose, Putzmeister offers both technical advice and training for service engineers.

Project consultation increases efficiency

One of PSP‘s strengths is professional advi-se on the handling, storage and delivery of high-density substances. In the mining industry, the company‘s is often consulted by operators and planners long before the plant is commissioned.

A key factor in this is that the engineers at Putzmeister Solid Pumps GmbH bring

The modular pump head of the new Putzmeister mining pump HSP 25100 SP

together their specialist knowledge of the machines and their experiences in pum-ping high-density solids, with the pressure and flow characteristics of the media and in calculating and configuring pump systems. This, along with details about the procedu-re and the desired delivery rate, allows bet-ter alternative solutions to be developed. This pays off - in lower costs and faster pro-cesses with increased safety. n

For further information: www.putzmeister-solid-pumps.de

Simple opening of the pump heads for quicker inspection and replace-ment of wear parts

Clever detail solutions:

Mining

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The Putzmeister wet shotcrete machines are used worldwide.

Here, the SPM 407 P works in a copper mine in the “copper belt”. This is the name for Africa‘s biggest copper mining region deep in the heart of the continent.

Deep in the heart of the dark continent

The SPM 702 is represented at the trade fair stand by its big brother. The light-weight, compact concrete pump can be used for a wide range of applications, such as concrete spraying, mortar injec-tion and other concreting projects.

It is very well suited to narrow tunnel pipes and can be used optimally both for securing the head with shotcrete, and for floor and arch concreting of crossways.The pump is available with a truck-moun-ted chassis or a carriage-like base struc-ture.

Handmade shotcreteIf equipped with an additive tank, it is con-structed on a double-axle long trailer.

The integrated metering device guarantees additive delivery proportional to the con-crete output and therefore guarantees eco-nomical and efficient use of the expensive chemicals. n

Of course, the machine operators have received intensive training at the time of commissioning. This is part of the worldwi-de Putzmeister Service, which ensures that our customers are able to make the most of their new machines. n

Mining and tunneling

The Bauma innovation for concrete spatter in mines and tunnels is specially designed for small cross-sections, with its boom reach of 8.5 m.

The new SPM 4207 is the result of the experience made on construction sites throughout the world in recent years with the predecessor model SPM 407.

The highlight:

Even in the PC variant with additionally integrated screw compressor, it remains as compact and flexible as the predecessor model. This was a particular request from customers and makes its use significant-ly more mobile and independent than with the previously available machines with similar dimensions.

The basis for this is an intelligent chassis concept as a platform, on which different customer-specific requirements can be rea-lised. During development, great emphasis was placed on a very robust frame, which is adapted to the highest stresses of wor-king in a tunnel.

Other advantages of the new shotcrete machine:

• a cost-saving Additive Management System• an on-board computer with multi- linguistic colour display for showing per- formance data, mixture breakdown, error diagnostics, warnings, etc.• safety driver‘s cab in accordance with the ROPS/FOPS ordinance• xenon working lights• protected support legs• optional turbocharger for diesel engine for use at high altitudes

In addition, there are option packages, which can be adapted to the different con-ditions in mines and tunnels, such as: mine tyres, cable drum with up to 100 m, cataly-tic converter, diesel particle filter, integra-ted fire protection system, high-pressure cleaner or a water pump (operable both via diesel and electric motor). n

The new SPM 4207: concrete spraying specially for small tunnel cross-sections

Basic data SPM 4207 P SPM 4207 PC

Lenght 6,250 mm 6,970 mm

Width 2,000 mm 2,000 mm

Height 2,450 mm 2,450 mm

Weight 6,900 Kg 8,400 Kg

Spraying arm / Reach Aliva 302 / 8,5 m Aliva 302 / 8,5 m

Theoretical output 4 – 20 m3/h 4 – 20 m3/h

Concrete maximal pressure 65 bar 65 bar

Climbing ability longitude (SAE norm) 48 % 35 %

Engine 47.5 kW 47.5 kW

The SPM 4207 PC in use in a copper mine in Aljustrel (Portugal)

Further information: marketing@putzmeister.es

Dry run in simulation

You have to learn the right way to con-trol shotcrete machines. In order to avo-id unnecessary material consumption and beginner‘s operating errors, Putz-meister has developed a simulation pro-gramme with which you can learn and practice the operation of the control units virtually.

You are welcome to try out our simulation at Bauma.

Mining and tunneling

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Nothing is so tempting as a low price. But imitation parts can often be more expensive and not everything that has the same number is always the same. APS manager, Uwe Tichy, describes the differences.

PM: Mr. Tichy, with Putzmeister genuine parts, you are trying to clearly distinguish yourself from offers by so-called pirates. Why?UT: First and foremost, we want to ensure that the machines work reliably and safely for our customers. The higher the availa-bility of our pumps, the more satisfied our customers will be. Often, however, minor details such as poorly fitting replacement and wear parts can cause faults which lead to an unexpected failure.

PM: But reality shows that they work well at times.UT: In this case working well simply means that the machine runs. The question is whether or not it pumps economically. Unnecessarily high downtimes or exces-sive wear costs are not noticed in some circumstances. Here, it is clear that the price of a part is often only one side of the coin. Service life, effects on the pumping behaviour of the machine and operational safety are just as important and cost-intensive, but are not as easily measurable as the price.

Beware of cheap parts and dumping offers!

PM: What are the differences in the imitation parts?UT: Concrete pump manufacturers need larger quantities of parts than the imitators and have also learnt from the mistakes of the 90s and made their replacement part prices more marketable. Therefore, the imitators have to make savings in order to remain cheaper. They do this by cutting costs in terms of the material, processing or by deliberately ignoring safety regula- tions and standards.

PM: Do you have an example?UT: Yes. If, for example, you put less natu-ral rubber and, consequently, more soot into a rubber component, it will naturally be cheaper. But the abrasion values, tear-resistance and therefore the service life will suffer significantly. This occurs above all in seals and delivery pistons. It is only partially dependent on where the part was produced, for manufacturers too make international purchases. The only important thing is that the part com-plies with the technical requirements and quality regulations.

PM: But customers must keep an eye on their costs, and not all of them always need a high-quality part.UT: That‘s true. That‘s why Putzmeister genuine parts includes a wide range of wear parts and delivery lines. The range includes very cost-effective parts, which

are perfectly adequate for a machine with a relatively low output per year. These che-aper parts can also be a good alternative in regions with less abrasive aggregates. On the other hand, wherever the annual out-put is very high, we recommend using our highly wear-resistant parts, which we are continuously developing and optimising.

PM: And is this ultimately worth it for the customer?UT: We are convinced that it is. Even with the “cheap” genuine parts, the fit, quality and interaction with the other components are just right. The quality requirements are documented during the design stage and in the drawing and do not develop at random during production This is evident not least of all in the fact that we offer service life guarantees in many cases, or service contracts through to a full service agreement. In this case, with our genuine parts, we take on the risk our-selves and can say that, in our experience, this is also worth it for us.

Copies can also be dangerous.Here is a cheap hose clamp, which was cast instead of forged.

PM: How can I recognise a genuine part?UT: Unfortunately, this isn‘t quite so easy as there are many counterfeits with PM marking or which are promoted as being “from original manufacturer”. Imitators and dealers are not deterred by anything in this respect. - In principle, the most reli-able and easiest thing to do is to buy the parts from the manufacturer or one of its authorised sales partners. n

The differences between genuine (left) and copies (right) are not always as obvious as with these oil filters, but they are nearly always bad for the customer.

Uwe Tichy

Director After Sales and Parts Service

Services

It is in particular during times when con-crete pumps are utilised less that invest-ments in ongoing maintenance prove to be a kind of “insurance” against cost explosions.

In such times, unplanned high costs due to failures or the replacement of expensive components can no longer be generated at short notice via earnings.

One easy way of lowering costs is to fit a bypass filter, which significantly improves the oil quality by means of fine particle fil-tering. Examples from maintenance agree-ments with this option show that even after 4000 operating hours the hydraulic fluid did not require replacement and there was no damage in the hydraulic system.

Keep costs down with inspection and maintenance

Depending on the region and the aggre-gates available there, all parts that come into direct contact with concrete during pumping are subject to high levels of wear. These parts include the S transfer tube, spectacle wear plate and rings, etc. and last but not least, the delivery line. The dif-ference in wear by low to highly abrasive

PM wear parts – top grade in two quality levels

Installation of the filter has therefore alrea-dy paid for itself after the first oil change is due, as the costs of the filter, depen-ding on the size of the machine, are rough-ly equal to the costs of the oil change. The oil quality is simply inspected at the 500 hour service, together with the operabili-ty of the filter.

For more information on this and on com-plete service packages through to the full maintenance agreement, speak to the PM service specialists at the trade fair stand or anytime after the trade fair. At Putzmeister Services, in addition to the technical aspect of the solution, you can also obtain important tips on correct main-tenance and operation in the context of inspection and training packages. n

materials can be extremely great. To redu-ce part costs and extend the replacement intervals, Putzmeister uses high-quality genuine PM wear parts even for standard equipment.

So, for example, the Duro 22 hard built-up welded spectacle wear plate can achie-ve a service life of 40,000 m3 with average concrete. Moreover, due to the manufac-turing process, typical cracks occur duri-ng the cooling down period, which are a characteristic of great hardness and wear-resistance.

In terms of even longer service lives, Putz-meister is exhibiting a new generation of hard metal wear parts at the trade fair. The hard metal plates, which are applied to the full surface with no cracks, have been addi-tionally reinforced at the critical edges. This has improved the wear characteri-stics overall and prevents early breakage of individual plates. n

Wear under control

Anyone who values safety and wants to use his delivery line to the full can-not avoid checking or measuring the wall thickness. Two devices for doing this can be tried out by the machi-ne operator in the service area on the Bauma.

These are ultimately simple devices for reducing wear costs.

A mobile bypass filter extends the service life and makes savings on oil changes

The latest version of the PM spectacle wear plate consists completely of hard metal and has up to 6 times higher ser-vice life than built-up welded parts.

Services

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To date, there has been a serious pro-blem for businesses wishing to process site-made mix with a plastering machi-ne. Although sand is locally available in abundance in regions like South America or the Middle East, it could often not be used even there in the pumps which were used. The new Putzmeister P 13 KA 230 plastering machine can already pro-cess virtually every type of sand up to a grain size of 10 mm. This has been made possible by redesigning a KA 230 type piston pump which can also handle the most arduous of plastering tasks.

Many companies on construction sites around the world have themselves found a way of producing their own mixes direct-ly on site. However, the locally available sands which used to be employed for pla-stering by hand are often unsuitable for processing in conventional pumps. As a result, suitable sand has to be bought in and in some cases transported to the construc-tion site across considerable distances. The costs which this generated were once the main reason why many companies were unwilling to switch from manual work to machine technology.

The piston pump P 13 – the “offroad plastering machine”

Putzmeister used machines – first class from second handThe demand for used machines in manufacturer quality is uninterrupted. But beware: With second hand truck-mounted concrete pumps in particular, it is not necessarily obvious whether or not the apparently cheap offer of a used machine dealer is also actually worth the price.

For only the manufacturer has the tech-nical know-how and detailed knowledge of the construction of individual compo-nents and on the method of operation of electronic or hydraulically controls. That‘s why Putzmeister is presenting the PM used machinery centre in a separate stand area.

For every currently available machine, detailed documentation with photos, tech-nical data, mileages, operating hours, etc. is available. In addition, examples show how thoroughly reworked the second hand con-crete pumps restored in the manufacturer‘s plant actually are, or what work could still be performed by the manufacturer – and at what cost.

This includes, for example, replacing wear parts and bearings, inspecting and, if necessary, replacing functional fluids, per-forming refits, updates of technically com-patible software and final acceptance, just like for new machines. n

This is no longer a problem thanks to the new P 13 from Putzmeister with the KA 230 piston pump. The KA 230 was spe-cially developed for processing all local-ly occurring types of sand up to a grain size of 10 mm and even the most difficu-lt of mortars.

The allrounder for all hardnesses

The new KA 230 dual piston pump has a specially developed larger pump head and has been specifically optimised to handle difficult types of material. It is extremely robust and low-wearing. It operates accor-ding to the successful dual piston principle with one working piston and one compen-sating piston. It can also be used to pro-cess other materials, of course, such as prebagged internal and external plaster, bentonite slurries, finishing plaster, insu-lating plaster, cement plaster, lime cement plaster and even light wall mortar. Thus, it has proven to be a surprisingly versatile allrounder that can be used in any difficu-lt situation.

When designing the whole P 13 concept, Putzmeister kept in mind that this machine is intended for use mainly on sites around the world where the harshest of conditions

Internet: www.putzmeister.deYour contact persons via e-mail: wehnera@pmw.de and marcecm@pmw.de

That is our goal: Satisfied customers with machines that are as good as new ones.

Of course, after years of operation, the work performed is apparent on used machines.So that you do not notice its age, they are restored at Putzmeister by qualified technicians.

can be found. A deliberate decision was therefore taken to use as few electronic components as possible. All functions and operating elements of the P 13 are pure-ly mechanical and therefore particularly robust and insusceptible to malfunction.

Diesel power package with offroad quality

The P 13 is driven by a 2 cylinder diesel engine with 12.5 kW. With this, it achie-ves a delivery pressure of up to 40 bar. The compulsory mixer, vibrating screen and pneumatic remote control on the spraying machine are practical equipment that come as standard. On request, the P 13 is also available with a fully road-approved chas-sis. This means, the „offroader“ can get to any construction site easily.

Therefore the new piston pump from Putz-meister is a real match for any challenge around the world. n

Internet: www.mortarmachines.com

The robust piston pump proves its worth worldwide under the toughest conditions.

Premiere at Bauma 2010

This year again, Putzmeister Mörtel-maschinen GmbH will be present at the Putzmeister Group‘s stand. Here, it will exhibit an extensive cross-section of its product line. In addi-tion to screed conveyors, plastering machines and fine concrete pumps, products such as paint pumps, fine plaster spray pumps and Dynajet pro-fessional high pressure cleaners will also be on display.

However, Putzmeister Mörtelmaschinen is not only presenting a full range of further developments and innovations at Bauma. In Munich, an exclusive complete product line will be presen-ted as an innovation.

ServicesMortar machines

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BAUMA booth layout

Putzmeister at Bauma 2010

Truck-mounted conrete pumps

BSF 20-4.09 SANIMABSF 36-4.16 H LSBSF 42-5.16 H LSBSF 49-5.16 HBSF 58-5.16 H LSBSS 70-5.16 H

Pumi truckmixer pumps

PUMI 24-3.67 CSPUMI 31-4.89 SRotor pumping unit

Telescopic Belt Conveyor

Telebelt TBS 130

Mining and tunneling

Sika PM 4207 PCBSA 1003 DAllentown AST 25

Mining

HSP 25100 SP

Solutions for the prefabricated parts industry

BQ 06

Stationary concrete pumps

MX 30-3 MultiBSA 1004 DBSA 1408 EBSA 2110 HP DBSA 14000 SHP D

Mortar machines

Mixokret M 740 D

Mixokret M 760 DHBS

Mixokret M 700 E

P 718 TD

P 13 KA 230MP 25S5 EV/TM

SP11 BUR

Services

CPD – Project consultationAPS – Customer service and spare partsDelivery line systems

Used machinesCustomer trainingsErgonic control systemsFleet management

All rights and technical amendments reserved · 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. · © 2010 by Putzmeister Concrete Pumps GmbH · Printed in Germany (3.51003)

EsserOpen air area block F9, stand no. 906 / 7

BrinkmannOpen air area block F9, stand no. 906 / 8

Strobot 406 SStromixer D 1000Trans Mix 3500 LB

Dynajet UHP 170Dynajet 350 md

Dynajet 800 me

PM 4300 GB