Volume : 2 Issue : 6 Q3 2012
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Projects in Progress
Bridging India with Schwing Stetter Equipment See page 5
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Notable Projects
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Product Focus
10
Technology
Concrete Facts
“Do you know that Schwing Stetter India's Batching Plant factory is one of the largest Batching Plants manufacturing facility in the world ”
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MD’s Message The last quarter was one of the most challenging times for the entire construction equipment manufacturing industry. Besides the sluggish market, the equipment manufacturers had to face further challenges due to increasing trend of exchange rates, stagnant interest costs and in many States, especially in Tamil Nadu, huge power cuts substantially adding to the cost of the products manufactured. Schwing Stetter India have taken up all these challenges in their stride and have implemented many projects to stream line their production facilities, increase efficiencies by cutting down avoidable expenditure and so on. Schwing Stetter India have also used this sluggish time to train their employees, especially the blue collared workmen on organisational development initiatives focussing mainly on the frontline warriors. Over 450 workmen are being trained on a specialised tailor made program in vernacular language, titled “Inspire & Win”. Schwing Stetter India plans to cover 100% of its workforce in the days to come. With the help of another training organisation, Schwing Stetter India has also rolled out a program on “Quality of Work Life” for workmen and front line engineers together on the same platform and on “Quality of Life” for newly married workmen along with their spouses. We strongly believe that these programs are bound to energise them and bring in positive energy in the system. In the meantime, the recent announcements made by the finance ministry like FDI in multi-branded retail, 49% of FDI in Aviation Industry and other policy reform initiatives being taken by the government has come as a great relief to the already sluggish sentiments. We are sure that the steps taken by the government will go a long way in re-enforcing our confidence on the Indian Market and the growth of construction, construction equipment industry. I wish you all and invoke the blessings of the almighty, especially during this festive season starting with Dussera, Eid, Diwali, Christmas and finally New Year 2013. All the best,
Kohinoor Square Project
Projects in Progress Schwing Stetter with L&T team carried out water cleaning system to avoid the wastage of concrete in pipelines. This method helped to save the concrete and ensured proper cleaning of pipelines for trouble free operation. With the help this system an average of 2 m3 of concrete per pour has saved. The customer has also used separate placing boom SPB35 to achieve fast progress and maximum output. Concreting at this high-rise project is going on smoothly at 210 meters vertical height with the joint efforts of Schwing Stetter India and L&T team.
A prestigious commercial project “Kohinoor Square” is under construction at Dadar (Mumbai). It is city's one of the tallest commercial tower standing 52 stories built by L&T ECC. Schwing Stetter India has contributed for building three towers at Kohinoor Square. L&T approached SSI to plan the concrete method and high-rise pumping for achieving the maximum output in concrete placement. These three towers at Kohinoor Square project is a mixture of commercial, residential and multilevel car parking facility.
Concrete Pour An average of 4,000 m3 of concrete is produced every month for past 36 months comprising various grades of concrete. Around 1,51,340 m3 of concrete has being produced till date out of which Schwing Stetter equipment has produced 1,37,801 m 3 . The balance concrete is procured from Ready-mix Concrete Suppliers. During early stage of basement and raft construction, M1 Batching Plant with BP3500D Concrete Pump produced 53 m3 of M50 grade concrete continuously.
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EQUIPMENT USED
NO.’S
Batching Plant
One M-1 and One H1.25
Concrete Pump (SP – 2800 FGV)
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Concrete Pump (SP – 1800 HDRC)
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Concrete Pump (SP – 3500 HDR D)
1
Separate Boom Placer (SPB - 35)
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Transit Mixer
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CT News "Best CEO of India" Awards
Safety Award
Schwing Stetter India recently received "Safety Appreciation Award" for D6 and D15 Units from National Safety Council (Tamil Nadu Chapter) for the year 2009 with recommendations from Inspector of Factories. The award was presented by Mr. S.T. Chellapandian, Minister of Labour, Tamil Nadu.
Mr. Anand Sundaresan, Managing Director of Schwing Stetter India received award for the “Best CEO of India”, under “Corporate Excellence Awards”, constituted by Stars of the Industry Group, Mumbai. The award was presented by Mr. Koushik Chatterjee, Group CFO, Tata Steel and Mr. Arun Arora, Chairman, Edvance Learning System, honoring for his excellence in the industry over the years. The occasion was graced by other dignitaries and members of the corporate and press.
Concrete Seminar at IIT
V. G. Sakthikumar is now Co-chairperson, Mechanisation Committee of BAI V. G. Sakthikumar, Chief Operating Officer (COO), Schwing Stetter has been appointed as Co-chairperson, Mechanisation Committee for the year 2012-13 by Builders' Association of India (BAI). In this new role, Mr. Sakthikumar will act as a catalyst for the construction industry.
The Indian Concrete Institute (ICI) and Indian Institute of Technology, Madras (IIT M) organised a two day national seminar on Modern Equipments for Concrete Construction in IIT- Chennai. In this unique and specialized gathering Schwing Stetter India shared its expertise in equipment for concrete placement and tunnel concreting which was presented by Mr. John Keenan, Schwing Gmbh. The event was attended by all the professionals, developers, manufacturers and suppliers to name a few.
7m3 Transit Mixer on Tata Chassis Schwing Stetter India and Ta t a M o t o r s j o i n t l y organised a road-show in Bhubaneswar to launch Schwing AM7 Transit Mixer on Tata Motors LPK 2518 chassis. During this event Schwing AM7 Transit Mixer on Tata chassis was displayed along with presentation on specifications of the products. The event was attended by the local RMC companies, hirers and contractors.
Exemplary Leader Award
Another award was bagged by Mr. Anand Sundaresan, Managing Director, Schwing Stetter India, for “Exemplary Leader Award”, constituted by the 3rd Asia's Best Employer Brand Awards 2012. The award ceremony took place in Singapore and was hosted by the Employer Branding Institute, World HRD Congress with CMO Asia as Strategic Partner and endorsed by Asian Confederation of Businesses.
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“SSIPL is the only company which can provide total concreting solutions and also provide customised products as per customer requirement” Mr. Mahesh Kanneganti, Managing Director, M/s. KBC Infrastructures Pvt. Ltd.
Notable Projects Schwing Stetter pump at Modak Sagar Tunnel
NCC Hydropower Project Schwing Stetter India has contributed for the successful completion of NCC (Nagarjuna Construction Company) Shorang 100 MW hydropower project at, Rampur, Simla (Himachal). The first power project of NCC has completed major concreting smoothly with joint efforts of Schwing Stetter India.
Pratibha Industries in joint venture with Austria-based ÖSTU-STETTIN Hoch- u. Tiefbau GmbH has done long-distance pumping at 1180 meters at Modak Sagar site using Schwing Stetter SP3500HD Pump. Schwing Stetter India has supplied its equipment for concreting the Modak Sagar Tunnel linings. The tunnel is situated at the west end of the MVP project area approximately 100 kms outside the city of Mumbai.
NCC approached SSI for planning the concrete methodology to complete their hydropower project successful where concreting was very critical. SSI equipments has done major contribute for this project by producing concrete of 60000 m3 for the construction of DAM, HRT, DSB, Surge shaft, Anchor Blocks, Pressure shaft and Powerhouse.
This project involves the construction of a 7.5 km long tunnel of 4,100 mm diameter with allied works such as intake and pipeline for transportation of water. The tunnel is laid around 90 meters below the ground level, which will have their intake close to Modak Sagar dam, and their outlets within the same existing service and bifurcation chamber at Bell Nallah. Pratibha Industries experienced that working with the innovative idea of long distance pumping was one of the challenging jobs it has faced during this project. But with the dedicated expert team's support from Schwing Stetter India, this job was accomplished with great success, setting a new benchmark.
The customer has used only SSI equipment comprising of two CP18, One CP30 Batching Plant, three SP2800, one SP1800 E, One 350D concrete pump and 18 No.s Transit Mixer for the successful execution at this power project. The best achievements are 850 meters horizontal pumping for HRT gantry concrete by SP2800 pump and SP1800E has done up to 1500 meters further as relay pumping system.
CP30 Batching Plant at Dabolim Airport, Goa
Two SP2800 pumps completed twelve anchor blocks of pressure shaft at the level of 300 meters vertical and 800 meters inclined. And two CP18 plants were erected beside excavated road on the hill, by shifting through narrow and high gradient roads and these two plants has produced major concrete for the project.
SP1400 at Universal Infraworld An SP1400 Concrete Pump has done 3000 m3 of M25 & M30 grade concrete at Universal Infraworld, Guwahati. It has pumped 150 meters horizontally and 7 meters vertically. The real estate project was given to a PMC ( P r o j e c t Management Consultancy) division named “Banka & Associate” for the entire t e c h n i c a l supervision.
Construction work of the new integrated international terminal building of the Dabolim airport, Vasco, Goa is going on in full swing and about 80 percent of the work has been completed till date. The project which was awarded to the Consolidated Construction Consortium is expected to get completed by the end of this year. Consolidated Construction Consortium has used Schwing Stetter CP30 Batching Plant to construct this airport. The plant has produced 54500 m3 of both M25 & M30 grade concrete in a span of 23 months. The customer has also used Schwing Stetter Transit Mixers to easy transportation of concrete to the site.
The project was awarded to three different contractors for the construction of six blocks. Customer preferred SP1400 concrete pump for more output as it can be used by all the contractors. The customer is happy about the after sales support provided by Schwing Stetter India.
The new integrated international terminal building was the need of the hour considering the fast growth of the air traffic at Dabolim airport. The state-of-the-art integrated international terminal building is being equipped with modern facilities.
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Bridging India with Schwing Stetter Equipment
Concreting Solutions
A large numbers of Bridges, Flyovers and Elevated MRTS Structures are being constructed all over India for better and faster commuting. It also provides connectivity to different parts of city in a country which forms a faster transportation system. Many compilation of bridge structures built in India is being concreted by equipment of Schwing Stetter India.
Our team of concrete experts look insight to the problems and provides solutions to guide the customer about easy concreting. Customers call us right away to discuss the project before the commencement of construction and to find the possible concrete placing solutions for complicated project. Our team provides the best solution which would make the most sense and would be most efficient. We have a complete systems approach, helping the customer from the beginning of the project.
Bridge constructions are the most complicated because of unexpected difficulties which are faced during the construction and especially concreting. The latest trends and developments in design and technology have lead to many challenges during the construction of bridges.
Some of the concreting solutions given by Schwing Stetter are; Selection of equipments for batching, transporting, placing as per project requirements.
Challenges Faced in Bridge Concreting The quality and reliability of the concrete is crucial to safe construction and lifespan of the bridges. To ensure the same, different ingredients of concrete has to be mixed homogenously to produce a perfect mix of concrete and place in fastest time. Bridge concreting is done using up to M80 grade concrete mix. Critical requirements like casting blocks need maximum strength in minimum possible time for Pre-stressed or Post-tension casting.
Use of RVM's for concrete transfer from shore to off shore. Mounting option for Batching Plant, Transit Mixer, Separate Placing Boom on barge and on lattice frame.
Use of minimum space required for setting up our boom placer which helps in traffic as well as casting yards. Pipeline placing and cleaning systems for casting yard, offshore and high structure application.
Some of the other issues and challenges in concreting of bridge projects are stiff consistency concrete producing, placing concrete girders using cranes (e.g. Metro Projects) along heavily crowded roads, transportation and laying of concrete pipes on the sea or river for concrete placement. And to overcome these concreting difficulties Schwing Stetter India not only manufactures different types of advanced concreting equipment but also provide concreting solutions to the customer.
Equipments used
Bridge Project by SSI
The most commonly used Schwing Stetter equipment to place concrete for bridge projects are: Batching Plants CP30 and M1, which provides a homogenous mix of concrete. Concrete Pumps like BP350, SP1800 and BP3500 are designed with two valve technologies, flat gate valve (FGV) and Rock Valve, which makes the tedious process of conveying concrete to long distances and also to pump stiff mixes for casting.
Schwing Stetter India has contributed in many critical & landmark bridge projects in India. The different types of bridge projects where our equipment are used are Beam or girder type bridges (regular), Cable stayed bridge like Bandra Worli sea link, Suspension bridges like bridge over Ganges in Kolkata, Elevated Highway Bridge like Pune Kothrud bypass, Bangalore elevated highway bridge and Rail bridge for metro & monorail like Chennai, Delhi, Bangalore and Cochin Metro, Monorail project at Wadala and Vallarapadam (Kochi) railway bridge.
Transit Mixer- 6m3 are usually used to transport the concrete for bridge constructions. These Transit mixers comes with modern design, simple handling and cost effective. Separate Placing Boom - 28 meter to 42 meter and Boom Placer - 17 meter to 36 meter are used for faster completion of concrete placement. These equipments take on the challenge presented by the bridge projects.
SSI has also done bridge projects like Hebbal flyover at Bangalore, Kosi river bridge at Assam, White house bridge at Navi Mumbai, Delhi gate bridge and Sayan bridge at Surat, to name a few.
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“SSIPL not only provides the high quality service with finest concrete mixing, but also demonstrates commitment to excellence at every turn. Highly Recommended” Mr. Shripad Shikhare, Project Head - Dosti Vihar, Dosti Realty Pvt. Ltd.
Events BAICON- Chennai
Schwing Stetter's Rock Night
Schwing Stetter India recently organised 'Rock Night' meet for Pump operators at Kochi-Kerala, Bharuch and Ahmedabad-Gujarat. During this event SSI covered topics like preventive and periodic maintenance of rock valve pumps, safety operation tips of concrete pumps.
Schwing Stetter India recently participated in “BAICON-2012” an International Expo on Construction Equipments held in Chennai. The event was organised by Builders Association of India Southern Centre.
As a part of the event small exercise of pump operator competition was also conducted and based on skills and knowledge, gifts were distributed. Rock Night provides a platform to the pump operators to raise their skills on implanting safety and maintenance awareness.
National Record in concrete pouring by Lafarge On July 24th, 2012, at Chennai, M/s Lafarge A&C India's RMX Siruseri Plant has set a new record in RMC segment in India by pouring 1014 m3 of concrete in 24 hours. Schwing Stetter's M1 Batching Plant along with the 13 Transit Mixer and SP 1800 Concrete Pump were engaged to achieve this.
This exhibition was inaugurated by Mr. K.V Ramalingam, Minister for Public Works, Govt. of Tamil Nadu. The event was attended by most of the BAI members, Construction companies and contractors in Tamil Nadu. Schwing Stetter India showcased its S43 Boom Pump, 7m3 Transit Mixer, CP18 Batching Plant on trailer and SP1400 Concrete Pump which were big attraction.
Schwing Stetter
CP18
This “Mega concrete pour” work was awarded to M/s Lafarge by SMIPL for Green Tree project was targeted to finish 1700 m3 in 48 hours. The Lafarge Siruseri Plant team planned well to achieve the set target, uninterruptedly delivered and pumped the concrete to this customer using Schwing Stetter M1 batching plant and set a record of 42.25 m3 per hour. M35 Grade thermocouple concrete was the requirement for Raft foundation of the project.
Engineered for Mobility
Lafarge supplied 1014 m3 of concrete in 24 hour and completed the total requirement of 1700 m3 in 46 hours. The Lafarge team efficient planning, performance of Stetter equipments and customer cooperation at site were ultimate for this success.
The latest innovation of Mobile Batching Plant to meet the batching requirements comfortably in remote conditions.
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Customer Speaks Interview with Mr.P.Sampath, Managing Partner, P R Readymix India Pvt. Ltd., Coimbatore. About P R Concrete P R Readymix India Private Limited was started in 1975 by Mr. P. Pappi Reddi is a leading provider of ready-mix concrete in Coimbatore. We stand ahead of our customer's expectation and we are one of the ISO Certified concrete ready-mix provider. We are good in time management and complete the work as per the schedule on time. We keep up the promise to provide better quality with affordable price. Our company has a rich history in service, innovation and continuing growth. We are very happy & proud to introduce our three plants which are located at Kalapatti, Palladam & Salem running successfully. With Hard work, straight forward, quality and innovative approach our team has placed us in the books of many esteemed customers.
Equipment Used
KTVR Knowledge Park of Engineering &Technology, Periyamathampalayam, Coimbatore
Our company commissioned first Schwing Stetter CP30 Batching Plant on March 2001, which is still working successfully. Currently we have SSI equipment like Batching Plants CP30 two Nos. M1 Batching Plant, Concrete Pumps BP350D, BPL350, SP1400, BP1800, Transit Mixers 6 m3, 8 m3 and F12 Belt Conveyor.
Ananya Shelters Nana Nani Home, Vadavalli & Thondamathur, Coimbatore
Why SCHWING Stetter India?
About some of its landmark projects:
We are pleased to say that Schwing Stetter India is one of oldest & most valuable supplier serving our needs in supplying the materials at right time. We purchase all our major equipment such as Batching Plant, Concrete Pumps, Transit Mixers, Conveyor Belts and spare parts from Schwing Stetter. SSI provide us the material with good quality, they are prompt in service. We would like to appreciate Schwing Stetter's way of approach. It has also recognized all our suggestions and feedbacks are very well.
Eye Foundation, R.S.Puram, Coimbatore Sri Ranganathar Polytechnic College, Athipalayam, Coimbatore Pollachi Institute of Engineering & Technology, Poosaripatty, Pollachi We have also supplied concrete for most of the Windmill foundations in and around Coimbatore
Interview with Mr. Akash Mittal, Director, Ved builders Pvt. Ltd., New Delhi About Ved Builders Our company was started in the year 1994, We are among one of the top RMC suppliers in our region. We are also Govt approved contractor and specialise in DDA projects.
About some of its landmark projects: We are currently doing 50,000 m3 DDA road project in Delhi. Our company is coming up with housing project in greater Noida. We have constructed 480 EWS flats at Mayor Vihar phase 3. We have constructed ICDAR building at institutional area, Vasant Kunj. We have constructed additional floor at Kirodimal College.
SSI Equipment Used Currently we are using M1 Batching Plant with full silo setup, Schwing Stetter Transit Mixer 10 Nos. and LP1400 concrete pump.
Follow us on
Why Schwing Stetter India?
https://www.facebook.com/schwingstetterindia
We are pleased with Schwing Stetter's equipment and its performance. There are many reasons to select Schwing Stetter's equipment because of its German quality and wide range of products it offers. We are happy with the sales team because of their good relationship. We are also happy with after sales support as they are quick and are highly skilled technically.
https://twitter.com/schwingindia
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“One Stop Convenience” Mr. Santhosh Rao Balmuri, Managing Director, M/s. Saivani Constructions
Product Focus 3
Nimo 3 m Transit Mixer
TSR 30.14 - Shotcrete Machine TSR 30.14 is a Universal Shotcrete Machine driven by a diesel engine, equipped with a shotcrete pump and a telescopic boom for concrete spraying. The shotcrete pump has the ability to deliver 33 m3/hr of concrete at 59 bar. The telescopic boom can be extendable upto 14 meters. The boom can be rotated to 270 degree about Y-axis. Both the pump and boom are driven by an electric motor. Emergency operation of boom is carried out by a separate geared pump driven by vehicle's diesel engine. Spraying head consist of three hydraulic motors. Two hydraulic swivelling motor is for adjusting the nozzle rotation and one hydraulic
Concrete on the go is a key factor today that has helped the RMC industry evolve. Transit mixers are the most visible among the range of concreting equipment. But with the common 6 m3 class transit mixers are not being allowed to ply inside city roads during the peak hours. It's because the transit mixers are offered on 16 tonner or higher capacity trucks which is classified as HCVs. Schwing Stetter's Nimo, a 3 m3 transit mixer mounted on a 10 tonner truck (with 8.25 X 20 tyres) comes under the LCV category. Thus enables the customer, to drive the transit mixer into the city even during peak hours and helps to continue the concreting activities without any delay. Similarly, the smaller capacity also means a more economical option for sites where it does not make sense to send a large transit mixer, for the contractors.
Features
Power-controlled hydrostatic drive unit with variable pump mounted directly to the diesel engine. Power to both axles is transmitted by means of hydrostatic variable motor via transfer case. Steering of vehicle is switchable to four-wheel steering, front-axle steering and crab steering.
Nemo comes with the shorter truck wheel base of 3250 mm and an overall height of 3250 mm of fully built vehicle. This helps the customer to drive the vehicle comfortably through narrow congested lanes and in hilly regions, where sharp turns are quite normal and unavoidable.
Open drivers stand equipped with ROPS/FOPS shelter. The vehicle can be driven in both directions by rotating the stand to 180 degree. It also has Hydraulically driven water pump of 200 bar for cleaning purpose.
The unique ability of NIMO, running through all kind of roads and narrow passages, enables the user to carryout concreting continuously. Thus, SSI lends the hand in the process of construction.
Schwing Stetter S43 Boom Pump
the construction site thanks to their low height that saves space and time. Schwing's SX outriggers are designed to be compact, with a fast set-up time. The S 43 SX requires an 8.3m outrigger spread (the spread is the same, front and rear) for maximum stability.
Schwing redefines standards in the 40 m class with its S43SX truckmounted concrete pump. Schwing RZ boom design combines the “Roll and Fold” boom with a Z-fold boom at the tip to offer 270 degree flexibility at the last boom section. The boom folding system also enables concreting work right up to the vehicle bumper. With an overall length of less than 12 m on a standard chassis this compact boom package does not extend beyond the machines outlet.
The standard Schwing Remote Control features twin joysticks for proportional boom control and pin-point accuracy. In addition, Schwing's Vector control is the only system providing two-way communication between the pump and operator.
With the 270-degree Z-fold section at the tip of the boom, operators have a myriad of options for placement while shooting concrete up to 42.3 meters vertically, and 38.1 meters horizontally. The S 43 SX has an unfolding height of 8.7 meters for those low overhead situations and a slewing range of 740 degrees to suit many job site requirements. Its pipeline is a full DN-125 mm diameter.
The “Generation 3” concrete pump is a lowmaintenance, 164 m3/hr unit that provides long, slow-stroking action. The all-hydraulic design utilizes the Schwing Big Rock Valve, promoting maximum filling efficiency of the material cylinders even with harsh mixes.
The Schwing's SX front outriggers extend along an arc, do not have to be swivelled or telescoped and can fit into even the smallest gaps at
An open circuit design provides continuous hydraulic oil flow for fuel efficiency, filtration and cooling. The S 43 SX can do infrastructure work, light commercial projects and bridges. In conjunction with the DN-125 pipeline, contractors can perform high-volume pours or provide a slow delivery with infinite volume control. A 600 liters water tank on the unit helps with clean-up at the yard or on the job site. Consistently lightweight design makes this machine a universal and flexible longboom pump - both for medium-sized operations in downtown urban areas and on large construction sites.
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Project Abroad
Castle Concrete Pumping Builds a Castle
Schwing S 47 SX one among the range of pumps used in this project
“It was an interesting project because the owner's wishes changed as the project evolved, so it was back to the engineers to redesign or expand a portion.” Paul Tingle , an Italian contractor for day-to- day operations , who oversaw the hundreds of pours performed by Castle Concrete Pumping, “Rich, Obe and their operators work very hard to earn and keep the business. Dario set his sights on a dream and Castle helped deliver the dream. I use their pumping service all the time for my custom home business.”
Schwing S 47 SX at project site
The Castello Di Amorosa is an authentically-styled, 13th century medieval Tuscan-style castle and a Napa Valley landmark in California,thanks to the vision of the owner Mr. Dario Sattui and the dedicated construction crews that saw it through to completion. Started as an 8,500 sq.ft. project, it grew to its finished size of more than 121,000 sq.ft. It incorporates medieval construction techniques that qualify the structure as a true castle complete with moat, drawbridge, high walls, towers, a great hall, courtyards, secret passageways and, of course, a torture chamber.
Of course what self-respecting castle would be complete without a wall around it. Fortified defensive walls that were designed to be 18inches thick were expanded to three-feet of poured concrete to be consistent with dimensions of 13th century castles. Most of the concrete is covered with locally sourced stone attached by mortar and brackets. More than 8,000 tons of stone were hand-chiseled in keeping with the owner's desire for authenticity. In olden times when castles took years to build the stone would often change as construction progressed and new sources were found. So it is with Castello Di Amoroso. The exterior appearance takes on a different look depending on when it was built.
As the project grew, so did Mr. Rich Castle's Castle Concrete Pumping. “In order to service the project, both longer and smaller booms were required, “explains Mr. Obe Elliott, Pumping Manager for Castle Concrete Pumping (CCL), “We grew to having a large fleet with over a dozen different sizes of Schwing concrete pumps available, ranging from 17 to 58-meter boom lengths and several Schwing line pumps, including an SP 500, SP 750, SP 1000, and chassis-mount city pumps. And we used them all at one time or another on this project.” CCL pumps were constantly on call for the project.
Schwing KVM 52 pumps the three-foot thick fortified defensive walls
Castle's pumps handled all of the mixes supplied for the job including lightweight concrete that was used for upper levels that were not in the original plan. Foundations that were constructed for fewer stories, had to accommodate higher loads when additions were added. Plus this was the first castle built to Seismic Zone 4 specifications. “We kept an eye on the sand in the half-inch lightweight mixes and kept the specific gravity in line, “Mr. Bob Abbot, General Manager for the Ready-Mix firm explained, “The Castle pumps had no problems.” Short six mile hauls kept the temperature of the mix in spec even on the hottest days. Most loads were 4,000 psi, 6.2 sack blends with 15 percent flyash. “We supplied lots of colored material, “according to Abbot, “Mostly mortar but also concrete.”
Schwing KVM 39X performs at Castello di Amorosa
The physical dimensions of the site are 250-feet by 600-feet, a large area that became more cramped as the project outgrew the original plans. “Small boom pumps played a big role in the pumping, explains Elliott, “Our 17, 24, and 25-meter pumps were used extensively for tight access and low clearance pours, but as the project design grew and elevations increased, the longer Schwing booms were needed for deep footings, mat slabs, and tall walls, where the small footprint provided by their X-style and Super X outriggers paid off.”
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“We have been associated with SSI since the inception of the our company. Our loyalty & performance of Schwing Stetter has made us biggest RMC Player in Faridabad.” Mr. Pankaj Garg, Director, Garg RMC
Tech Ascertaining concrete pressure using Nomograph One of the major requirements of concrete pumping is ascertaining which pump will be suitable to do a particular job. To identify the right pump for the right job, we should know exactly what are the variables which affect the pumping. Since ascertaining the pumping pressure is most important before we start the pumping operation, a tool to find out the same can be of immense help.
Nomograph for ascertaining the pumping pressure By means of the nomograph the pumping pressure for a delivery output can be ascertained provided that the horizontal and vertical placing distances, the consistency, the installed bends and the pipeline diameter are known. The nomograph is based on values compiled by SCHWING over more than 15 years on pumping jobs in Germany and abroad. It has turned out that even under the most varied site conditions the values recorded on the basis of the nomograph, i. e. the theoretical ones, and the actual values are in adequate conformance. The deviations are within a range of 10%. It can be derived that the pumping pressure to be expected can be ascertained with accuracy adequate in practice.
Pipeline diameter In the upper right corner of the nomograph straight radial lines are assigned to the various nominal diameters of the pipelines (DN 100DN 150). The resistances due to tapered pieces, by means of which the pipelines are connected to the concrete pumps, have already been incorporated in the nomograph.
Indicated below are the essential points for ascertaining the pumping pressure by means of the nomograph.
Proportional value of the pipeline - horizontal placing distance
3750 3300 2750 2250 1875 1125
Nomograph Technical identification number
150
The proportional value of the pipeline is to be interpreted as the entire pipeline laid, where at the flow resistances of the pipe bends are reckoned among the horizontally laid pipeline. SCHWING recommend bends with a radius of r = 1 m for all diameters. The proportional value of a 90 deg. bend with a radius of r =1 m is 3, independent of its diameter; this means that its flow resistance corresponds to that of a 3 m long horizontal pipe section. Hence it follows that a 30°. bend with a radius of r = 1 m has a proportional value of 1. If for example bends totalling 540°. are installed in a pipeline system, this is equivalent to a proportional value of 540 °/30° =18.
Pipeline dia (mm) 125
70 60 50 40
100
30
150 132 110 90 75 45
20
10
Working Power (Kw)
80 For vertical placing add 0.25 bar per meter of level difference
Flow rate in cum / hr
112
10 120 110 100 90
80
70
60
50
40
30
20
Pressure in bar
Vertical distances are added as a pressure extra when ascertaining the placing pressure. They are not considered in the proportional pipeline value. The length of the vertical line is included in the total pipeline.
50 K2
100 60 K3 70
Concrete consistency
200 80 100
120
Slump of fresh concrete (mm)
140
160
600 500
400
The concrete consistencies are indicated as radial lines in the left lower sector. They have been ascertained by experiment in relation to the spread measure. The indicated slump is based on empirical values.
300
Proportional value of pipeline (m)
Please download a high resolution copy of the above nomograph from http://www.schwingstetterindia.com/Nomograph.pdf
Pumping pressure
Concrete output as a function of the work factor of a concrete pump
The pumping pressure can be read on the left horizontal coordinate of the nomograph. No possible pumping height is considered in this value. The pumping pressure ascertained by means of the nomograph refers to the pressure at the pumping piston (concrete piston) of the concrete pump and is not to be confused with the pressure in the hydraulic system. The pressure in the delivery pipeline immediately after the reduction pipe is depending on the ratio of the taper up to 15% lower than the pressure at the piston and is decisive for dimensioning the pipeline.
To determine the pumping pressure by the aid of the nomograph start from the concrete output plotted on the vertical coordinate. The velocity of the concrete flow in the pipeline and thus the pumping pressure depend on the delivery output. Hence it follows that one must start from the actual output, i. e. The delivery output which creates the rate of flow. If a site intends to pour 50 m3/hr, then a concrete pump with a max. output of 50 m3/hr can achieve this output only by pumping 60 minutes per hour. Such ideal conditions are seldom complied with on sites. In practice, the work factor of the concrete pump will possibly be 75% only (i.e. 45 minutes per hour), since the concrete distribution often requires repositioning of the pipeline or the approach of truck mixers to the concrete pump is impeded because of confined space on site. A work factor of 75% means that for a desired output of 50 m3/hr the concrete pump must place 50 m3 of concrete within 45 minutes which results in a delivery output of approx. 67 m3/hr.
Determination of pumping pressure with regard to vertical placing distance The static pressure resulting from the pumping height is added to the pumping pressure which has been ascertained by means of the nomograph. It amounts to approx. 0.25 bars per meter of level difference. Only the level difference is considered, thus the ascending gradient of the pipeline whether laid vertically in a building or inclined on the ground is irrelevant. Thus the final concrete pressure derived using nomograph can be used for proper planning and use of your concreting resources. Happy Pumping!
10
Tech Wall thickness and wear of pipelines Concrete delivery pipelines are subject to wear. Its extent depends on the quality of the pipe material, on the flow velocity of the concrete, on the concrete pressure in the pipeline as well as on the hardness, shape and mixing ratio of the aggregates. The pressure in a pipeline system drops from its maximum value at the pressure source towards the outlet. This means that pipes close to the pump are subjected to higher wear. Therefore preferably new pipes or pipes with thicker walls should be used here. For the most part, pipes used for placing concrete have a wall thickness of 4.5 mm. They are only sufficient for moderate pressures. A pipe section DN 125 with a wall thickness of 4.5 mm, for example, can only absorb a maximum pressure of 112 bar. The table shows the wall thickness as a function of the pumping.
Pressure with differing pipe diameters For high and highest pressures of up to 200 bar Schwing offer pipes with a wall thickness of more than 7 mm. These pipes use flanges for the Schwing cup type tension couplings. In case the wall thickness falls short of the minimum requirement, which depends on the maximum possible pumping pressure of the concrete pump, the pipe sections particularly those close to the concrete pump must be replaced. Danger of accidents!!! The wall thickness of pipes can be easily checked with an ultrasonic measuring unit or by spot-drilling, if necessary.
Minimum Pipeline Thickness Chart 3000
210
130 1800 1600 1400
m m 0
0 15
m m
ID
1. This chart assumes a safety factor of 3:1. Higher safety factors may be required in some circumstances. 2. Wear reduces wall thickness. Thickness must be checked on a regular basis.
ID
2000
5
Note:
PE PI
5m m
150 140
12
PE PI
HE
160 2200
ID
PI PE
170
m m
ID
12
CONCRETE PRESSURE BAR
2400
180
10
2600
190
AT TR EA TE D
2800
PI PE
200
120
3. Pressures may be limited even more by clamp style or pipe end used.
110 100 90
1200 1000 800
4. The chart is based on 52,000 PSI tensile strength. Heat treated calculations are based on a 50 percent increase in tensile strength.
80 70 60 50
600
40
400
30
5. The chart is for pressure calculations only. There is no allowance made for mechanical forces due to improper support or restraint.
20 200 0 PSI
6. The chart does not take into account metal fatigue caused by pressure cycles.
10 0 0
1.27 .635
2.54
1.905
3.81
3.175
5.08
4.445
6.35
5.715
7.62
6.985
8.89
8.255
10.16
9.525
11.43
This chart is intended for concrete pumping applications and is subject to the notes, assumptions, and conditions noted above. Any other use of this chart is not recommended.
12.7
10.795 12.065
PIPE WALL THICKNESS in mm
Designing Truck Mixers for Evolving New Trends Star Batcher
Schwing Stetter has invested in R&D and constantly works on designing Truck Mixers to meet the fast Changing Concrete specifications. Pioneering the transit mixer industry for over 13 years in India and 75 years in the world, Schwing Stetter India manufactures concrete truck mixers with capacities ranging from 3 m3 to 10 m3. The mixers are available in C, C2 and N versions that enable quick discharge and maintenance free operation. Available with options of slave engine and PTO driven technology, Schwing Stetter mixers are known for their high fuel efficiency. A design made of the finest grade SG Steel, these mixer have a long life and are supported by the best after sales service support in the country.
11
“Because of the Good reliability of Schwing Stetter Equipments and service, they have become best tool in our industry” Mr. Thiyambak Pandey, Assistant General Manager, P&M, WELSPUN India.
Dear Customers, Greetings!! In this issue, we have discussed about the SCHWING Stetter's contribution in supplying equipment for Bridge Construction Projects. We are proud that our machine played vital role aiding Customers to build landmark Projects across mighty Brahmaputra, Ganga Land across the Sea in different parts of the Country. We are also pleased to share with you a report on Construction of a Castle in 13th Century Medieval Style where our Boom Pumps and Trailer Pumps were extensively used abroad. We have also covered a brief insight to the Wall Thickness and Wear of the Pipelines. Our machines continue to set record in different segments like one with Lafarge where 1014 cubic meter of Concrete was poured in 24 hours using a M1 Batching Plant. We have also brought out an “On the Spot Report” No.3 about Modak Sagar Tunnel and we would like you to inform that more such reports will follow in the months to come. We would like to invite all Builders Association of India Members to visit 40th IFAWPCA Convention scheduled to be held in Kochi from 6th to 9th January 2013 were SCHWING Stetter is the main Sponsor. With the monsoon over, we see increased activity and interest amongst our customers and we hope that this trend grows further and helps the Industry to come out of slow phase of growth. I would also like to thank all the Customers who took advantage of our special offers for the Service Center's during the Monsoon Scheme. Happy reading!!! With best regards,
V.G. Sakthi Kumar, COO sakthikumar.vg@schwingstetterindia.com For any feedback regarding this newsletter, email at editor.ct@schwingstetterindia.com
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GERMANY Schwing Stetter is the pioneer in manufacturing of concreting equipment for the past 78 years. Quality products, strong design capabilities and the experience from developed countries during its growth phase make Schwing Stetter the preferred choice world over. Batching Plants I Concrete Pumps I Transit Mixers I Concrete Recycling Plants I Belt Conveyors I Separate Placing Booms I Shotcrete Pumps ISO 9001:2008 :: OHSAS 18001: 2007 :: ISO 14001:2004 F 71 - 72, SIPCOT Industrial Park, Irungattukottai, Sriperumpudur Taluk, Kancheepuram District,Tamil Nadu - 602105. Phone : 044 2715 6780 / 781, 47108100 / 33555588 Fax : 044 27156539 Visit us at www.schwingstetterindia.com MUMBAI 022 25624863 / 64, 30718300 / 33555588 I NEW DELHI 011 3092 8500 / 33555588 HYDERABAD 040 6615 1783 / 33555588 I BANGALORE 080 4243 8400 / 33555588 KOLKATA 033 3322 3300 / 33555588 I COCHIN 0484 4055984 / 3355558 I AHMEDABAD 079 40244200 / 33555588 PUNE 020 26055651 / 2 / 33555588 I CHANDIGARH 0172 3957500 / 3355558 BHUBANESWAR 0674 2463999 / 3355558 I GUWAHATI 0361 2234738 I RAIPUR 0771 2562325 Published by Schwing Stetter India in Chennai. All Correspondence to be sent to editor.ct@schwingstetterindia.com Designed and Printed by A.L. Senthil Kumar :: For private circulation only, not for sale.
Many more to come...
October 2012