Construction Machinery ME July 2019

ISSUE 93 JULY 2019

PLUS

NTA LLY AT E P F O R E W O P E TH A ENTA EQU

RS VOLVO P ROSS EMISSION TIE HOME AC

A N C E ES M R O F R E P G N I T F I AC UPL FT JOB PL HEAV Y LI L TRUSSES T WO STEE UBAI ARENA ON NEW D

E T E R C N CO N A L P

UMPS P D N A S R MI X E

ER X I M 4 0 3 1 RR E H B E I L E TH E K I OR L T T C I E K S W T E N HOW N PING THE CEME IS RESHA

MOVE MORE, FASTER If you’re shifting large amounts of material over longer periods of time then you should be considering rigid haulers. They excel on larger areas where roads are better maintained, carrying up to 95 tonnes in one cycle and standing up to the highest impact loading from the biggest shovels. Even the massive R100E is capable of speeds of up to 50 kph, while the R45D, R60D and R70D vary between 57 and 65 kph – all with highly efficient fuel consumption, helping to keep your cost per tonne right down. The operator environment is second to none, with excellent all round frontal visibility and impressive 360° bird’s eye view of the work zone thanks to Volvo Smart View. Get up close – arrange a viewing with your local Volvo dealership.

CONTENTS JULY 2019

36

6_NEWS The latest news from across the region and further afield.

14_THE POWER OF PENTA Volvo Penta’s head of industrial segment, Giorgio Paris, tells CMME how his company views the Middle East engine market and its future.

18_UPLIFTING PERFORMANCE CMME takes a behind-the-scenes look at how a contractor used two giant crawler cranes to lift a mega truss atop Dubai’s Coca-Cola Arena.

24_LOFTY PERCH Tower crane specialist Wolffkran shares insights into its Middle East

12 SPOTTED IN BEmLagGcIraUwM lers

operations, new developments and its emphasis on learning for growth.

R E W O P RAW EN 34_TOP T s to Top ten tip

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e follow for m

er heat.

t the summ

es to bea and machin

12

Twin De ind dismatle w turbine

ent sector.

E PL A N T ting the cem E ec R aff C e N ar O sit mixer 36_C r’s 1304 tran t like Liebher How new ki

and safety.

M PE D U ach, power P re Y in L ts H en G m ve 40_ HI ps see impro ncrete pum co d te n u o Truck-m UR AT FERVO C B O B t kit. ’S Y with compac H FAMIL C ld business N o E e R ad F ec _ d 4 4 a threettany build sons in Bri Father and

14

18

24

40

2

EDITORIAL JULY 2019

GROUP MANAGING DIRECTOR RAZ ISLAM raz.islam@cpitrademedia.com +971 4 375 5471 EDITORIAL DIRECTOR VIJAYA CHERIAN vijaya.cherian@cpitrademedia.com +971 4 375 5713 EDITORIAL EDITOR ANIRBAN BAGCHI anirban.bagchi@cpitrademedia.com +971 4 375 5715

THAT HEADY FEELING

SUB EDITOR AELRED DOYLE

As some people in the CMME family may know, I am an avid motorcyclist. When not thinking about the latest marvelous crane, loader, aerial work platform or telematics technology that has burst onto the scene, I can be found musing about the latest Kawasaki, Honda or Ducati to have been unleashed on the road.

Riding a motorcycle gives me a heady feeling of freedom and relieves the stresses that accumulate as part of everyday life. It’s a pill I take at least twice daily to feel at my best, once on my way to CMME Towers and again on the way back.

But why am I telling you this, you may ask? Well, I admit I started with a digression, but let me come to the point: riding a motorcycle, unfettered by the steel cage of a car with its confining A, B and C pillars, and unrestricted by the strip-like glass of a windshield, I get wider views of the city around me. This often has me noticing the latest construction projects coming up and being executed around me, which, as you know, form the grist to the mill of materials that we present to you in CMME. One of these projects that came into my view – and that I kept my eyes on for a while – was the Coca-Cola Arena build in Dubai’s City Walk area. When two massive tower cranes were spotted rising skywards in the vicinity of the site, I knew something interesting was afoot.

And in this issue, we bring you a behindthe-scenes look at what actually was afoot – the lifting of two mega trusses, each weighing 850-plus tonnes, to the top of the structure in a difficult, coordinated tandem lift by two Demag CC 8800-1 crawler cranes.

From the remote fabrication of the massive trusses, transportation to the site on SPMTs, selection, mobilisation and rigging of the cranes, to the actual lift itself, with

SALES EXECUTIVE

each Demag hooking on to either end of the trusses with spreader bars and gently raising them to the place of their final installation – the entire process was a complicated one.

No matter how much I delve into the world of machinery – or perhaps the more I do – I never fail to get a heady feeling about these projects.

Elsewhere in this issue, we talk to Volvo Penta and Wolffkran about their activities in the region and take a look at the world of concrete machinery, where new models are making their presence felt in the way the sector works. The new Liebherr 1304 mixture, designed by the German giant based on feedback from its customers, including those in the Middle East, is reducing the number of trips a liquid concrete supplier needs to make for delivery to job-sites, improving overheads. New truck-mounted pumps are also aiding the sector with technology that enables them to rotate 360 degrees while pumping the slump high.

What’s also reaching high is the temperature as we enter the peak of the Middle East summer. This is also the time when some of us look forward to the heady feeling of a holiday in a cooler faraway land, but here’s reminding those of us who’ll have to work under the scorching sun to stay hydrated and take extra care.

aelred.doyle@cpitrademedia.com ADVERTISING

TOM BROMLEY tom.bromley@cpitrademedia.com +971 4 375 5496 DESIGN ART DIRECTOR SIMON COBON simon.cobon@cpitrademedia.com DESIGNER PERCIVAL MANALAYSAY percival.manalaysay@cpitrademedia.com MARKETING MARKETING MANAGER SHEENA SAPSFORD sheena.sapsford@cpitrademedia.com +971 4 375 5498 CIRCULATION & PRODUCTION PRODUCTION MANAGER VIPIN V. VIJAY vipin.vijay@cpitrademedia.com +971 4 375 5713 DISTRIBUTION MANAGER PHINSON MATHEW GEORGE phinson.george@cpitrademedia.com +971 4 375 5476 WEB DEVELOPMENT MOHAMMAD AWAIS SADIQ SIDDIQUI FOUNDER DOMINIC DE SOUSA (1959-2015) PRINTED BY PRINTWELL PRINTING PRESS LLC PUBLISHED BY

Licensed by TECOM to registered company, CPI Trade Publishing FZ LLC whose registered office is 207 – 209, Building 3, Dubai Studio City, Dubai, UAE. www.cpitrademedia.com

Anirban Bagchi Editor, CMME

© Copyright 2019 CPI. All rights reserved.

While the publishers have made every effort to ensure the accuracy of all information in this magazine, they will not be held responsible for any errors therein.

Experience the progress.

Economic transport of concrete with the HTM 1304 • Ideal solution for High Flow Concrete • Longer lifetime • User-friendly design

Liebherr Middle East FZE P.O. Box 2540 Dubai Tel: +971 4 889 1740 E-Mail: ali.kassem@liebherr.com www.facebook.com/LiebherrConstruction www.liebherr.com

4

ONLINE JULY 2019

MOST POPULAR

READERS’ COMMENTS

FEATURED

CONSTRUCTION

HOW RETAIL DEVELOPERS CAN WIN FIGHT AGAINST ONLINE

Sharjah Airport Authority opens tenders for airport expansion project

You only have to look at the increasingly sparse town and city centres across the developed world to see that retail faces a major challenge.

CONSTRUCTION

Work starts on Swiss pavilion for Expo 2020

Feature: A bump in the road for driverless cars?

CONSTRUCTION

Kuwait’s CAPT issues resolutions for construction services

CONSULTANT

ACCIONA Producciones y Diseño reflects on construction of Qasr Al Watan

CONSULTANT

EmiratesGBC: Retrofitting is crucial for meeting carbon emission targets

Opinion: A new generation, a new style

I read the article (How retail developers can win fight against online) and was happy to see that I am not the only one that thinks we need to re-think the way we design malls in the region.

We may be behind the curve when it comes to the evolution of the retail space but online sales are now keeping people away from the traditional shopping experience and it will inevitably hit here. We need to not just be thinking about the technology but also the economics of mall operations and ensure that retailers are not priced out of the market.

That is the only way that we can continue to offer choice and also value for consumers. We also need to ensure malls maintain strong, separate identities. In the future we won’t need more malls, but better ones too.

Name withheld by request

MAINTAINING YOUR UPTIME, PROTECTING YOUR BOTTOM LINE

CONTACT US FOR MORE DETAILS: Yusuf Bin Ahmed Kanoo Building 832 Shaikh Ahmed Al Sabah Highway AL Hamriya 611 P.O. Box 45 Phone: +973 177 382 00 www.kanoo.com

Bobcat is a Doosan Company. Doosan is a global leader in construction equipment, power & water solutions, engines, and engineering, proudly serving customers and communities for more than a century. Bobcat and the Bobcat logo are registered trademarks of Bobcat Company in the United States and various other countries. © 2019 Bobcat Company. All Rights Reserved.

S W NE 6

PIONEER PASSES ON

SNORKEL FOUNDER BREATHES HIS LAST

JECTS, O R P W E N OFFICES, W E N , S E HIN AROUND K O NEW MAC O L E IVES – W T A MONTH I T S I I N H I T W E NE W WHAT’S N T A N O I G THE RE MAMMOET TOPS

Arthur Deshon Moore, founder of

RANKINGS

Snorkel and a serving board member

Mammoet has

of the company, died last month

emerged as the

aged 94. In an obituary, the global

largest crane

powered access equipment major he

company in

founded said Moore was a pioneer

the world on

in the access industry, known for his

the 2019 global

drive and determination in a career

top 100 largest

that “set an extraordinary example

crane-owning

and left a lasting impact on the

companies

global work-at-height industry”.

ranking published

His imaginative designs and

by International

pursuit of quality helped to shape

Cranes and

the industry in its infancy and set

Specialised

standards still followed today,

Transport.

Snorkel said, announcing the

Companies are

June 19 passing of its founder.

ranked by their IC

Moore developed 17 industry-

Index, calculated

defining models in less than a

Haulotte delivers 26 units to Turkish Technic

as the total

decade and built the foundation for

maximum load

Snorkel, today among the leading

moment rating

global manufacturers of aerial lifts.

of all cranes in a

He was probably best known for

fleet. While the

the Snorkel TB-42 telescopic boom,

total available IC

which became a standard in the

Turkish Technic has commissioned 26 new Haulotte powered access machines for its new service centre in the recently inaugurated Istanbul Airport.

According to Haulotte, Turkish Technic, a leading service provider in the aircraft maintenance, repair and modification sector, recently received the last Haulotte Star 6 PICKING unit in order to complete its main fleet, which now consists of more than 70 Haulotte machines. Acarlar Makine, Haulotte distributor in Turkey, has been supplying Turkish Technic with lifting equipment from the French powered access major for more than 10 years.

Serkan Acar, GM, Acarlar Makine, said: “The maintenance of aircrafts is highly regulated in order to ensure safe and correct functioning during flight. For this reason, high performance machines are required to finish the work on time by providing the highest safety

Index value of all

industry for many years, as well as the

crane companies

introduction of the first ‘big boom’,

this year was

which reached 38m in height.

levels for engineers and operators.”

A wide range of machines were chosen by Turkish Technic, Acar added. The order included products such as scissor lifts, articulating booms and electric vertical masts.

The Haulotte HA26 RTJ PRO and HA41 RTJ PRO articulating booms will be used to maintain the high ceilings in the hangars. These versatile machines have been designed to meet the expectations of operators in terms of performance and ensure cost-effective investment for the end user, said Haulotte.

Compact 12 electric scissor lifts and Star 6 PICKING vertical masts were also delivered for various aircraft maintenance tasks, Acar added. The new Istanbul Airport has been one of the most successful projects for Haulotte in recent years, with more than 300 machines used during the construction phase.

28,051,368 tonne-

Over the years, Moore’s industry

metres, an annual

contributions have been recognised

increase of 0.57%,

with honours like the International

Mammoet took

Awards for Powered Access Lifetime

the top spot with a

Achievement Award in 2016,

fleet of 136 lattice

and induction into the American

and 528 mobile

Rental Association’s Hall of Fame

cranes adding

in 2017. Following the acquisition

up to 2,850,000

of Snorkel by Don Ahern in 2013,

tonne-metres.

Moore became a Snorkel board

Sarens and ALE

member, providing his global

took the second

insight and product knowledge.

and third spots.

Don Ahern said: “For many years, Art Moore was a mentor to myself and others in the early years of the access rental and dealership business, and he ultimately became a close friend. He will be a great miss to Snorkel and the wider industry.”

8

NEWS ROUND-UP JULY 2019

NEW DIRECTION

JCB STARTS ELECTRIC MINI PRODUCTION

1,200-plus items sold in Ritchie Bros. auction

Global equipment auction heavyweight Ritchie Bros. put up an inventory of over 1,200 pieces of heavy equipment and trucks at its summer auction in Dubai on June 18 and 19.

Held at the Ritchie Bros. yard in Dubai’s Jebel Ali Freezone, the selection

LOXAM BIDS FOR RAMIRENT French rental giant Loxam has made a bid of €970m for Ramirent, with the latter saying it has recommended that its shareholders accept the offer.

The merger would create the largest rental business outside North America, with total revenues of €2.3bn.

of equipment up for auction included cranes, wheel loaders, hydraulic excavators, dump trucks and generators.

Up for bidding were more than 80 Caterpillar machines, including eight 966H wheel loaders.

Also available were over 30 cranes, including a

180t Zoomlion QUY180 unused crawler crane.

Smaller equipment such as backhoe loaders, skid-steer loaders, compactors and gensets were also auctioned.

Among the highlights were a 2011 Grove TMS900E hydraulic truck crane, three 2014 Zoomlion QY130V hydraulic truck cranes, three Komatsu PC8007 excavators, four Komatsu HM400-2R articulated dump trucks and two Cat AP655F crawler asphalt pavers.

According to Ritchie Bros, as it was an unreserved auction, there was no minimum bid or reserve price on the items sold. As with all Ritchie Bros. auctions, registering to bid was free and bids could be placed in person at the auction site or live online.

XCMG, ROLLSROYCE TEAM UP Rolls-Royce Power Systems and China’s XCMG have announced an alliance to develop the Chinese mining

The first fully electric excavator from

equipment

JCB has gone into production, with

markets. The two

the British brand saying the 1.9t 19c-1E

companies signed

model is the first such machine to be

an agreement

put into production by an original

in Xuzhou,

equipment manufacturer.

China, XCMG’s

According to JCB, the model has been

headquarters,

designed for both outdoor and indoor

to explore

applications and is five times quieter

opportunities

than an equivalent diesel-powered

for integration

machine. The company also says the

of Rolls-Royce’s

19C-1E delivers the same performance

MTU power

as a diesel-powered mini excavator in

and propulsion

the same capacity class, while reducing

systems, including

both internal and external noise levels.

MTU Series 2000

The new model comes with three or

and 4000 engines,

four lithium-ion battery packs providing

into XCMG

storage of 15-20kWh. The batteries have

equipment for

been designed to last the operating life

mining projects in

of the machine, according to JCB. It

China and abroad.

also has an on-board charger with 110V input for 12-hour recharging capability.

A 230V charging option is also available when required, with a recharging time of eight hours. A fast charge option will also become available, allowing a full charge in under two hours.

CAT, RIO TINTO TO AUTOMATE NEW MINE

Mining giant Ri o Tinto and Cate rpillar recently signed an agreement fo r the supply and supp ort of mining m achines, automation and enterprise tech nology systems for the new Kood aideri iron ore m ine in Western Australia. Unde r the agreemen t, Ri o Tinto and Caterpillar will work together in cr eating an automated min e operation that m ak es best use of data anal ytics and integr ation to enhance safety , optimise prod uction, boost mining m achine utilisatio n and lower costs .

9

XtreeE, Concreative in UAE 3D print unit Large-scale 3D printing AEC solution provider XtreeE and concrete 3D printing firm Concreative have signed a deal to open a new production unit in the UAE. The new unit will be operated by Concreative and aims to use 3D printing on 25% of new construction projects in the next six years, incorporating XtreeE technology.

XtreeE said the launch is in line with its strategy of structuring a network of more than 50 globally connected 3D printing units by 2025. The firm is also said to be partnering with Bjarke Ingels Group (BIG) architects on a new cultural project in North America, which will be announced later in the year.

XtreeE was founded in 2015 and said it recently won major investment from

TTWiiN Investment Partners, the innovation investment arm of US-based Thornton

PB LAUNCHES SERVICE AGREEMENT

DOOSAN HEAVY AND KHNP TO MAINTAIN UAE NUCLEAR FACILITY

TALLEST SCISSOR German powered access equipment

Tomasetti (TT). In 2015, TT helped develop Dubai’s the Office of the Future, a 2,000sqft structure designed

by Gensler and created using a 20ft-tall 3D printer.

“There is a huge misconception within the AEC industry that 3D printing is a technology only of the future. We see it as a technology of today. We are pleased to help XtreeE pioneer new applications that will enable project teams to push the frontiers of design through digital fabrication. XtreeE is not only on the leading edge of this technology, but has the capability to deliver optimised structures,” said Ray Daddazio, president of Thornton Tomasetti.

EMPOWER PROMOTES SAVING ON COOLING Emirates Central Cooling Systems Corporation (Empower) has launched a ‘Switch to 24 deg C and save more’ campaign to support sustainability from June to summerend. It will help reduce district cooling energy consumption by asking users to set their thermostats to 24°C.

20,000t heavy lift crane ship completed

maker PB has Nawah Energy Company

in the Al Dafra region in

introduced the

(Nawah), the company

Abu Dhabi, is expected to

world’s tallest

operating units 1-4

provide over 25% of the

scissor lift, with

of the UAE’s Barakah

UAE’s electric power, saving

a working height

nuclear power plant, has

up to 21 million tons of

of 37.5m. The new

signed a maintenance

carbon emission every year.

PB S370-24 ES 4x4

service agreement and a

A subsidiary created by

is 8.74m long by

separate long-term service

the joint venture between

2.40m wide, and

maintenance agreement with

Emirates Nuclear Energy

4.13m high when

Doosan Heavy Industries

Corporation (Enec) and Korea

retracted.

and Construction (DHIC)

Electric Power Corporation

and Korea Hydro & Nuclear

(Kepco)-Nawah will operate

measures

Power Plant (KHNP), for

and maintain the plant.

10.50m by

the UAE’s Barakah Nuclear

Mark Reddemann, Nawah

The platform

2.11m, providing

CEO, said: “DHIC, with

around 22.2sqm

decades of experience in

of space for up

DHIC will provide

providing quality components

to four workers

maintenance services and

to the global nuclear industry,

with tools and

qualified manpower to

is a robust addition to

materials, which

support routine and outage

our experienced group of

can total 750kg.

maintenance activities across

international maintenance

the four 1,400MW APR1400

service providers, and will

units at the Barakah Nuclear

support our quality-led

Energy Plant, according to a

operations and maintenance

statement.

of the Barakah Nuclear

Energy Plant (Barakah NEP).

Under the agreement,

The Barakah NEP, located

Energy Plant.”

Singapore’s SembCorp Marine has completed the build of a 20,000t capacity crane ship, SSCV Sleipnir, for Heerema Marine Contractors. The world record-beating vessel, now afloat, is 220m long by 102m wide and carries a pair of turret cranes, each rated to lift 10,000t in tandem or individual lifts.

Made by Huisman, the revolving cranes will lift their 10,000t maximum load to a radius of 48m, while capacity goes down to a high of 7,000t at a 62m radius and 4,000t at 82m. The maximum lifting radius is 102m. The auxiliary

hoist is capable of lifting 2,500t to 60m radius. The crane ship is also equipped with a pedestal mounted lattice boom crane lifting 70t at 12m radius.

The vessel can accommodate up to 400 people and is powered by 12 engines, which can run on either low-sulphur marine gas oil (MGO) or liquified natural gas (LNG). Engines are grouped three each in four engine rooms, and each engine is rated at 8MW for a combined 96MW of power. Heerema will use Sleipnir to install and remove offshore oil & gas installations.

10

NEWS ROUND-UP JULY 2019

VIRTUAL TOOLS

GENIE INCORPORATES BIM IN NEW GLOBAL WEBSITE

Lootah lease-to-own warehouses a GCC first

Lootah Real Estate Development (Lootah), the real estate arm of Lootah Holding, has announced the launch of the region’s first lease-toown model of industrial warehouses in Dubai, with construction estimated to start in two months.

Located in Dubai Industrial Park (DIP), the model will offer clients pre-built industrial warehouses at 2% down payment, with customisation options available for different business requirements.

Moreover, clients will have full ownership of the warehouses

NEW DEPTH FOR BAUER CUTTER Bauer’s BC 50 cutter on a Bauer MC 128 dutycycle crane has completed a 228m-deep bulk sampling job on the FalCon diamond mining project in Canada, the first trench cutter to achieve the depth in commercial application. The project, run by Rio Tinto and Star Diamond Corporation, aims to prove viability of the kimberlite fields.

within 10 years, with base price for individual facilities starting at $2.7m.

Lootah has acquired 278,709sqm of land in DIP for the construction of Senaeyat, the industrial warehouse development project, which will be completed in two phases.

Phase one will include the development of 92,903sqm, with four different builtup areas for warehouses – 1,858sqm, 2,229sqm, 2,787sqm and 3,344sqm. The second phase will have the same options, in addition to 4,645sqm and 5,574sqm warehouses.

Saleh Abdullah Lootah, CEO, Lootah Real Estate Development, said: “In phase one we will start with 20 warehouses, and in phase two we will look at constructing 30 more warehouses. Once we receive more responses, we will also consider expanding and providing our services in Abu Dhabi, the Northern Emirates and even outside the UAE.”

Terex-owned powered

current site to offer a

access giant Genie’s

contemporary digital

newly redesigned

interface enables us

Genielift.com website,

to stay more closely

which went live

connected with

globally in April,

customers online –

DEWA INVITES RFPS

now also includes

getting them what they

FOR FLOATING

building information

need to know, when

SOLAR PLANT

modelling (BIM) tools

they need to know it.”

The Dubai

to aid architecture,

Electricity and

engineering and

tool enables building

Water Authority

construction

professionals to have

(DEWA) has

professionals to plan

the insight and means

issued a request

their construction

for planning, designing,

for proposal for

projects digitally.

constructing and

firms to conduct

Aron Sweeney,

The new Genie BIM

managing building and

studies for the

Genie senior marketing

infrastructure projects

development and

manager – Digital,

more efficiently. In

delivery of floating

Terex AWP, said:

providing the resources

solar photovoltaic

“From researching and

to include Genie

(PV) plants in

planning to purchasing

products in projects, the

the Arabian Gulf.

and training, customers

BIM concept envisages

The scope of

are doing more business

virtual construction of a

work includes a

online. Refreshing our

project before it starts.

feasibility study, the technical requirements for a floating solar PV plant, an environmental impact report, a study of the marine requirements and other necessary safety studies.

ALE USES SPMT TO MOVE GIA CRAWLER CR NT ANE British heavy lift and tran

sport specialis using self-pr t ALE is opelled mod ular transpor move a 750t-c ters (SPMT) to apacity Man itowoc 18000 crawler cran lattice boom e between w ind turbine to Blanca wind wers at the Lo farm project ma in Patagonia, is using the cr Argentina. AL awler to inst E al l 16 w ind turbine ge The roads be nerators. tween the in st al la tio n sites, howev are too narrow er, for the crane, so ALE is mou on 36 axle lin nting it es of generatio n-3 SPMTs in file 18 configu a fourration. The SP MT fits within limitations of the the road, enab ling the cran to be transpor e ted whole, sa ving time over disassem bling, movin g and reassemblin g the crane, ALE said.

11

Bobcat expands telehandler range

Bobcat has expanded its telescopic handler line-up with the inclusion of the latest 8m TL43.80HF and 7m TL30.70 models, and now offers a choice of 13 rigid frame telehandlers for applications in construction, rental, recycling, waste and general industry, covering maximum lifting capacities

between 2.6-4.3t with lifting heights from 6-18m.

The compact equipment giant said the new TL43.80HF increases the lift capacity in the Bobcat range to 4.3t, combining this with a maximum lift height of almost 8m. The TL43.80HF is a compact telehandler that brings together high

productivity, robustness and rough terrain ability in the same machine, providing a new solution for heavy lift handling applications found in general industry, manufacturing, building materials, warehousing, quarrying and mining.

The TL43.80HF is also ideal for farming work, the

manufacturer added.

The TL43.80HF’s box welded frame, low load centre, long wheel base and new massive rear counterweight give it high stability, allowing Bobcat to minimise the overall dimensions of the machine, resulting in a width of only 2.30m and a length of less than 5m from the rear to the fork face.

The TL30.70, meanwhile, provides a maximum lift capacity of 3t and a maximum lift height of nearly 7m, for a wide range of applications in construction, rental, recycling, waste and general industry.

The model’s compact width of 2.1m in the 7m class makes for a compact and stable machine for easy pick- and-go or for lifting materials to height on housing and commercial property developments.

NEW SANDVIK 2 SERIES CRUSHER Sandvik has launched its upgraded 2 Series QI442 tracked mobile impact crusher, which comes with overband magnet, pre-screen, underpan feeder, ceramic blow bars and remote control as standard. The new model can be configured to work as either a primary or secondary machine, and can be adjusted for many output sizes.

12

KIT SPOTTING JULY APRIL2019 2016

DEMAGS DISMANTLE BELGIAN WIND TURBINE

W

hen crane service provider Aertssen removed for maintenance 58m-long rotor blades weighing 72t from an Enercon E-126 wind turbine at a height of approximately 136m, what appeared a routine job was actually a tricky challenge only made possible by the team’s extensive experience and two Demag CC 3800 lattice boom crawler cranes.

Aertssen project manager Peter Bertels says: “Before anything else, we had to decide which crane to use for the job. There were two options available: either a large crane that would be able to take care of the lifts by itself, or two more compact cranes that would tackle the lift in tandem.”

Ultimately, the team decided on using its two CC 3800 cranes, as they were more cost-effective, would be powerful enough when used together, and had the required reliability and precision characteristics. However, it was first necessary to make sure that ground-bearing capacity at the work-site in Estinnes in southern Belgium was sufficient for the two crawler cranes, as it had originally been calculated for the use of a single crane only, back when the wind turbine was first erected. Once cleared, nothing stood in the way.

A total of 52 truck runs across a distance of around 130km were needed to get the two cranes from the Aertssen branch in Stabroek to the site. A five-person Aertssen team then set up the cranes within a week. The team started by setting up the first crane, a bit farther away from the wind turbine, on the corresponding access road, then proceeded to set up the second one closer to the tower.

For the configuration, the team decided on the main boom variant with a 141m LSL and 12m

LF4 arrangement with an offset of 20 degrees. The Superlift mast had a length of 36m, and the crane was set up with 165t of counterweight and 50t of Superlift counterweight.

Once these steps were completed, the cranes and the Aertssen team were ready for the technically ambitious lifts: the 72t rotor blades not only had to be taken from a height of 136m and safely lowered to the ground, but also had to remain perfectly balanced while being lowered. To achieve this, the operator of the CC 3800 closer to the tower first guided a sling, hanging from a spreader beam with four-part reeving, around the tip of the rotor blade. The other crane’s operator then did the same. While ‘lassoing’ the rotor blades with the slings, the two crane operators depended on the instructions of Enercon employees on-site.

“The reason is that even though we’d installed cameras on the spreader beams, our crane operators were operating remotely and were therefore unable to determine whether the slings were at the right height. It was kind of like lassoing a tiny animal,” Bertels explains.

Once the two slings had ‘lassoed’ the rotor blade, the cranes swung them to the intended rigging points. Then it was time for the job’s tricky part. First, the cranes needed to rotate parallel to each other to get the blade out of the rotor. Once this happened, crane 1 had a gross load of 46t on its hook, while crane 2 had 36t. The operators were able to set down the blade at a radius of around 22m. However, the blade had to be kept perfectly horizontal at all times in order to prevent it from sliding off the slings, which is why digital spirit levels with wireless transmission capabilities were installed on the blades in advance.

13

“There were two options available: either a large crane that would be able to take care of the lifts by itself, or two more compact cranes that would tackle the lift in tandem�

14

HARD HITTER JULY 2019

THE POWER OF PENTA

ENGINE MAKER VOLVO PENTA IS AT THE FOREFRONT OF STAGE V AND ELECTROMOBILITY SOLUTIONS, WHILE ALSO PAYING ATTENTION TO LOWER TIER ENGINES POPULAR IN THE MIDDLE EAST POWER SECTOR, INDUSTRIAL SEGMENT HEAD GIORGIO PARIS TELLS CMME

T

he Middle East is not the place to find the latest in emission technology.

While most of the world’s advanced markets are already asking ‘what next’ after the introduction of engines compliant with Stage V emission standards, virtually anything goes in the Middle East, where Stage II and III engines still hold sway.

Despite this state of affairs, the Middle East is of huge importance to Volvo Penta, one of the largest engine makers in the world, at the cutting edge of engine technology and meeting emission norms. This is because it is the Swedish giant’s favourite proving ground for its entire product range, says Giorgio Paris, Volvo Penta’s Industrial Segment head and head of Region International.

Revealing the importance of the Middle East to his company, Paris tells CMME: “When we develop a product, the test engines are left in the Middle Eastern environment to run and be validated. All our field testing takes place in the region. And this is not just for those models that we sell in the Middle East; it’s for our entire product range sold globally.

“We have the opportunity in the Middle East to test our engines in the most challenging environment, which is why we use the region as our proving ground. Of course, at the other

end of the spectrum, when we need to test our engines for cold weather performance, we use our home conditions in Sweden to do it.

“But the Middle East, with its deserts, high temperatures, humidity, dust, sand and the general harsh environment, it’s definitely a good area to run tests. So, in general, our entire genset engine range is developed in this most challenging area. This means that the cooling systems on Volvo Penta engines are tropicalised, the air filters tested for dusty environments, and so on. We develop and optimise all our engines to work in such a challenging environment as the Middle East, which means that they can perform anywhere in the world.”

As a Volvo Penta veteran of 22 years, Paris is uniquely qualified to speak about how the Swedish engine maker has branched out globally and moved the paradigm forward in the development of industrial engines.

Chatting with CMME in Munich on the sidelines of Bauma 2019, he explains: “I have a geographical responsibility across three verticals, one of which is International. I also have a segment responsibility for Marine and Industrial Engines, and I’m the head of Industrial Engines at Volvo Penta, where I joined in 1997 and have since participated in the company’s extraordinary journey in the development of the industrial segment.”

The Middle East is a very important area for Volvo Penta, he says, not only from the point of view of developing and proving

15 Volvo Penta specialises in engines for various applications, such as off-road, construction, power generation and marine. It is an OEM supplier to many Middle East genset makers.

“When we develop a product, the test engines are left in the Middle Eastern environment to run and be validated.

All our field testing takes place in this region. And this is not just for those models we sell in the Middle East; it’s for our entire product range sold globally”

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HARD HITTER JULY 2019

engines, but also as a business market.

“The region is a big market for generators and gensets, and as we are very active within the genset sector, the Middle East is an area of the world that gives us very high volumes for our industrial segment.

There are many local players in this region, but it is also a target market for all major European and global companies.”

Volvo Penta is well placed in the region through important partnerships with some of the biggest names in the Middle East’s power and machinery sector, Paris says.

“In the Middle East, we have long-lasting collaborations with a number of importers. We do not operate directly with a market unit like we do in many other areas of the world. We are not present ourselves, but we have designated importers with whom we have teamed up for a very long time. For instance, around the end of autumn last year we celebrated 50 years of collaboration with Al Khorayef in Saudi Arabia, and very soon we will celebrate 50 years of collaboration with Al Masaood in Dubai and Abu Dhabi. We have another long-lasting collaboration with Orascom in Egypt, and yet another with Khonaysser Motors in Lebanon.

“So as you can see, we are talking about big players in the region. Most of the area is covered by these importers, some of whom are themselves genset builders, such as Khonaysser and Al Khorayef through their company Gulf Power, and so on. Apart from distribution of Volvo Penta engines,

they also use our products to manufacture their own gensets.”

The Middle East is a very saturated genset market, and while opinion is divided as to whether this is despite or because of being an energy-rich part of the world, Paris is quite certain that this dependence on fossil fuels and high-emission engines in the region is not going away anytime soon.

“I think awareness about environmental challenges is growing as a general trend in the Middle East, but it’s still low. When we

A big generator market, the Middle East gives Volvo Penta’s industrial segment high volumes through long-standing collaborations with importers who use and distribute its lower tier engines.

“We develop and optimise all our engines to work in such a challenging environment as the Middle East, which means that they can perform anywhere”

were at the Middle East Electricity (MEE) exhibition earlier this year, we heard that some governments in the region, such as in Lebanon, were investing a lot in solar power.

So over the years there will be a gradual switch towards more green sources of energy, but for the time being, these are markets that are not regulated for emissions. And that’s why they are still extremely volume-driven businesses.”

When CMME points out that Volvo Penta still opted to launch a new Stage V engine at MEE in Dubai this year, Paris explains that the decision was based on the importance of the event rather than the engine preferences of the regional market.

“We firmly believe that the MEE is one of the most important power generation shows in the world. Its participants are many of the regulated players as well, so the entire global power and engine sector comes to the event, including the most popular EU and American brands. It’s an important show where we also meet several customers from the regulated markets. So we felt it was the right time and place to present the Stage V engine, even though the product is not necessarily for the Middle East area.

But the exhibition was the ideal place to launch it because of the wide participation of customers from other parts of the world.”

With the Middle East a non-regulated market, what range of engines does Volvo Penta supply here, we ask.

“We still have our Stage II and III ranges, so we offer engines within the different emission delineations. For this market, we offer Stages II and III, and now we’ve gone up to Stage IV in some countries in the region, and of course we even provide Stage V wherever required,” Paris says.

“In the genset business, we start from a five-litre engine and have a range based on a family of four engine types. We have the five-, the seven-, the 13- and 16-litre engines. We start from 100KVa and go up to 800KVa stand-by. We believe we offer quite a large range of power nodes. We’ve done some great development work on the 16-litre, so we have an incredible power density within our biggest engines.

“And, of course, all the testing and validation of our product range is done in the Middle East region, so our products are well prepared to meet the major challenges of the region’s harsh environment, especially the high temperatures. And this is for our entire range.”

While OEMs such as Volvo Penta still make their lower tier models available in the Middle East, the world has moved on to Stage V and is progressing to even cleaner engines.

Research and development in companies such as Volvo Penta is obviously geared

17 around engines in the higher tiers. So where does this leave non-regulated markets in terms of the technological advancement that the new research is channelling into the more advanced engines?

Putting our apprehensions at rest, Paris reveals: “Basically, we work on the optimisation of our products rather than developing them from scratch every time we move to a higher emission level. It was two years ago at MEE that we presented our biggest 16-litre engine. Thereafter we have improved and extended the range upwards up to 800KVa. We’ve made this development through optimisation of the original product.

“A major driver of new development in our engine range is emission legislation decided by the various governments around the world. Normally, the engines that conform to the highest emission regulation are more complex in design and to manufacture. For lower emissions we use the same base engine and optimise it for the specific emission level.”

Paris says the next step for Volvo Penta is electromobility. Although this has not gained as much traction in the Middle East as elsewhere, there is still a surprising level of interest in the region.

“There are port operators such as DP World in Dubai who are demanding electromobility solutions for their terminals. We see these major fleet owners or port players very interested in our electric offerings. We work mainly with OEMs making reach stackers, terminal tractors and so on that are being used in these port operations.

“As far as I can see, the sensitivity in these sectors towards electromobility or electrified solutions is extremely high. The reason is that these port operators have global operations, so

the demand is up more or less everywhere. In China, part of the port of Shanghai is already electrified. DP World is interested in electric solutions for its operations around the globe.

A globally integrated business will have the same norms everywhere and will replicate best practices from one geography in another.”

Volvo Penta announced last summer that it plans to have electrified power solutions by 2021 for both land and sea applications, and Paris adds: “Some areas will be early adopters of electrified solutions, such as Europe, and others

Giorgio Paris, Volvo Penta’s Industrial Segment head and head of Region International, sees healthy interest in electromobility in the Middle East from the major fleet owners and port operators.

HIGH FIVE

STAGE V REDUCES FUEL CONSUMPTION BY 5% Volvo Penta says its Stage V off-road engines have proven extremely promising in field tests, boasting fuel consumption reductions of up to 5%. This reduces both CO2 output and total cost of ownership.

The range offers power from 143796hp, enabling customers to meet tough application demands. Each engine is specifically engineered to deliver optimum productivity, uptime and total cost of ownership, and is developed for ease of installation, operation and maintenance.

“We are keen to demonstrate to customers that Volvo Penta is

continuing to lead the way when it comes to engine and power systems innovation, most recently with EU Stage V,” says Johan Inden, president, Region Europe. “We are already seeing evidence that our customers understand this. Over the last three years, the Volvo Penta Industrial segment has increased its annual sales by an average of 45%.”

Volvo Penta’s Stage V range improves productivity through a seamless engine and exhaust aftertreatment system. Uptime has also risen by doubling oil change service intervals from 500 to 1,000 hours.

Volvo Penta champions ease of installation by ensuring commonality between different emission levels and also recently launched its first Stage V engine for mobile gensets, the D16, a neat and compact engine with lower maintenance needs, delivering around 3% better fuel economy (versus Stage IIIa) and reducing total cost of ownership.

where the adoption will come later, such as the Middle East. But there are many markets showing increased interest in electromobility.

So we will continue to work with the current technology and develop it further, such as we have done with the challenge of meeting the Stage V emission norms with our latest engines. We will work in parallel developing current and future technologies.”

For the present, in the Middle East the company needs to not only sell its fossil fuel engines but provide back-up too. Elaborating on the set-up for this, Paris says: “We have a parts warehouse in Dubai which we share with the rest of the Volvo Group. Then we have our importers, who are extremely well established in the region. Parts distribution and service is not a big issue for us at all. Our long-lasting cooperation with regional partners means that all of them have very good knowledge of our products. We run trainings on a regular basis for both service and sales staff. In fact, in April we ran a sales and after-market seminar in Dubai for our regional importers. We constantly develop our importers’ knowledge of our latest products, and intensively train and develop them to take care of Volvo Penta-powered machines.”

Being part of the Volvo Group also brings benefits such as knowledge and technology sharing. “There is constant inter-connection and cross-pollination between the Volvo Group’s various businesses, and we capitalise on each other’s developments. Through a combined effort, the Volvo Group is today at the forefront of both traditional and electrified equipment technologies, and we are at a stage where we can capitalise on these technologies.

It’s a win-win for everyone.”

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PROJECT REPORT JULY 2019

Dubai’s new 46,452sqm multi-purpose Coca-Cola Arena was developed by local real estate giant Meraas, and is touted as the only one of its kind between Istanbul and Singapore.

UPLIFTING PERFORMANCE

ANGITHA PRADEEP TAKES CMME BEHIND THE SCENES OF DUBAI’S COCA-COLA ARENA LIFT TO LEARN HOW A SUBCONTRACTOR PULLED OFF THE FEAT OF PLACING TWO 882T MEGA TRUSSES ON THE ARENA’S ROOF, USING TWO DEMAG CRAWLER CRANES

19

“Initially we had two proposals for the procedure, either to raise the individual mega trusses in a single tandem lift using two crawler cranes, or spread each mega truss into three pieces and lift them using temporary supports. But we found that a single tandem lift was faster�

20

PROJECT REPORT JULY 2019

“We used SPMT systems for transporting both the mega trusses from the assembly area to where they were being lifted. This ensured that we had sufficient space during its assembly. We used two lines of SPMT systems from Scheuerle, Germany”

W

ith a diverse portfolio of projects in the UAE, Dubai basedMeraas Holding’s deliverables are often seen as the region’s most intriguing and master-planned developments.

Hence, the excitement was palpable in late 2016 when it introduced the biggest indoor climate-controlled arena in the region.

Touted as the only arena of its kind between Singapore and Istanbul, the 46,452sqm Coca-Cola Arena – the developer signed a 10-year naming rights deal with the food and beverage corporation – opened to the public on June 6. Located in the trendy neighbourhood of City Walk, another experiential destination by the same developer, the

Al Jaber Heavy Lift used two Demag CC 8800-1 cranes for the job, each with a maximum lift capacity of 1,600t, maximum load moment of 26,160 ton-metres and boom length of 143.8m.

arena was designed and built to stand out.

Planned as a mixed-use space set to become a benchmark for entertainment venues in the Middle East, the 17,000-seat arena has become an instant hit, with the likes of Russell Peters and Maroon 5 already performing to sold-out events within a week of its opening.

Global architectural and design practice firm Populous created the concept design for the arena, while AEG Ogden, a venue management firm behind the O2 in London, Staples Centre in Los Angeles and Mercedes-Benz Arena in Shanghai, is in charge of the operation.

UAE construction heavyweight ASGC was given the design and build contract in 2016, and consultancy services were provided by Dar Al-Handasah. Assent, the steel arm of ASGC, was tasked with building and implementing the roof structure of the arena. The firm describes the project as a once-in-a-lifetime opportunity.

This is because supporting the roof of the arena entailed two mega trusses, each weighing 882t, being raised in a single tandem lift using some of the world’s biggest cranes. Including the support and additional steel structure, the total weight of the roof is 4,000t, approximately seven times the weight of the world’s biggest airline, the A380.

CMME sat down with project manager Mohammed Abd Elbaset and Assent sales manager Mohamed Magdy to talk about the planning and successful execution of the lift.

“First of all, we have this structure, the

21 components of which are two mega trusses that are 121m in length, 8m in depth and weigh 882t individually, which had to be raised to support the roof of the 4,000t arena. We also have 16 secondary trusses which had to be placed perpendicular to the mega trusses,” Elbaset says.

“Initially we had two proposals for the procedure, either to raise the individual mega trusses in a single tandem lift using two crawler cranes, or spread each mega truss into three pieces and lift them using temporary supports.

“But we found that a single tandem lift was faster comparatively, because lifting it in three pieces took more effort in terms of inspection, welding and fireproofing. A single lift also allowed us to avoid additional labour on the roof once the mega trusses were in place.”

Assent contracted Al Jaber Heavy Lift to operate the cranes, for which they used two Demag CC 8800-1 cranes, each with a lifting capacity of 1,600t, a maximum load moment of 26,160 ton-metres, maximum boom length of 143.8m and maximum tip height of 192m.

Elbaset explains that since the mega trusses were planned for assembly on-site, the installation sequence was discussed in advance with the main contractor and the lifting supplier to coordinate the position of the assembly and the lift.

“The engineering team started with studying the stability required during the assembly, and then connection design and general arrangement drawings

STAGING A LIFT

TECH SPECS TRUSS MEASUREMENTS

Inside floor space: 3,870sqm

Weight: 882t

Capacity: 17,000 seats;

Length: 121m

5,000 each on the 86mx45m

Width: 8m

arena bowl floor area, level

Bolts: 16,462

one and level four; 1,500-

Connections: 333

2,000 in the VIP suite halls.

Total man-hours spent

ARENA FACTS

on manufacturing: 85,000

Roof weight: 4,000t

Total man-hours spent

Total area: 46,451.52sqm

on assembly: 75,000

were approved. We then proceeded for fabrication and other assemblies which could be done at the shop within the allowable transportation limit. The full assembly of the mega trusses was done at the site, over temporary structures,” Magdy elaborates.

Assent confirms that it took 75,000 man-hours for the assembly of the mega trusses – approximately a month’s work for each one.

Once the first mega truss had been

Spreader beams were used under the crane hook for the lift to ensure greater stability of the suspended load of the mega trusses, which weigh 882t each and support the 4,000t arena roof.

assembled, it took 23 labourers and 10 staff members to shift it from the temporary support to the SPMT systems, which took five hours. The team came back the next day for the lift, which entailed 43 labourers, 10 staff members and another seven hours.

Magdy explains that there were a few challenges along the way, one of which was shifting the second mega truss to the core wall, since its assembly area was further away due to the placement of a mosque and some stores next to the lifting location. Once a full analysis was conducted to ensure stability and safety, the second mega truss was surmounted to the lifting location using the SPMT system.

“In fact, we used the SPMT systems for transporting both the mega trusses from the assembly area to where it was being lifted to. This ensured that we had sufficient space during its assembly,” says Elbaset.

Assent’s team managed to dismantle and shift the second mega truss onto the SPMT systems using 45 labourers and 10 staff members in six hours, while it took 21 labourers and 10 staff members three hours to manoeuvre the SPMTs to the lifting location. Raising the second mega truss to its final resting position took six hours, 45 labourers and 10 staff members.

“We used the two lines of SPMT systems from Scheuerle, Germany,” Magdy says.

The biggest challenge during the lift, Elbaset adds, was the huge weight of the single tandem lift, which had to be coordinated to distribute the load equally between the two cranes without any inclination.

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PROJECT REPORT JULY 2019

Magdy says its primary focus before the lift was installing the pot bearings, since the mega trusses were supposed to be resting on the pot bearings, in turn supported by four concrete core walls. “Once we lifted the mega trusses to the core wall, we connected it to the vertical steel support and kicker bracing to achieve vertical and lateral stability.”

He explains that once the mega trusses and the secondary trusses were in place, they used a synchronised jacking system to release all the temporary support and deprop the structure above the pot bearings.

Each mega truss had exactly 16,642 bolts and 333 connections.

Elbaset adds that the entire lifting sequence was verified using the finite element analysis model. Based on the analysis, additional temporary kickers were added in order to strengthen members subjected to high stresses.

Spreader beams were used under the crane hook for the lift, and Elbaset explains that this was done to ensure greater stability of the suspended load.

“The lifting points finalised were at each end of the structure. This was done because the structure had a main frame running to each end, which was connected to the pot bearing and was designed to transfer all the load to the pot bearing. So those points were the strongest locations to use for the lift. Since the points were at each end and we were lifting the trusses from their two sides, we used spreader beams, which were connected to the load by two wires.”

Given its location, scale and characteristic engineering, the arena will be seen as an entertainment venue of global standards in the coming years. It can host international touring artists, world-renowned comics, family entertainment, sports events, gala dinners, exhibitions and conferences, and other unconventional set-ups which cannot be accommodated elsewhere.

The interior is also versatile to suit different productions and technical specifications, with an adaptable design featuring a rolling modular stage, automated drapes and a retractable seating system.

The arena also features facilities such as four changing rooms, eight artist dressing rooms, more than 35 food and drink outlets, and 42 corporate suites. It is also wheelchair-friendly.

The 17,000-seater arena is split between 5,000 people on the 86m x 45m arena bowl floor area, 5,000 on level one, 5,000 on level four and 1,500-2,000 in the VIP suite halls.

DEMAG CC 8800-1

EXPERIENCED IN THE REGION Al Jaber Heavy Lift has used the Demag CC 8800-1 and its bigger version, the CC 8800-1 TWIN, in jobs around the GCC region before, with petrochemical projects as some of the prime examples.

A few years ago, the two cranes helped complete a series of super-heavy lifts on a petrochemical development in Qatar. The project involved a total of 143 lifts, 31 carried out using the 1,600t capacity CC 8800-1, and two lifts – installing two AGR (advanced gas reactor) absorbers, each weighing 1,300t – with the TWIN. The lifts were planned by Al Jaber Heavy Lift site manager Sebi Phillips over a period of 18 months, with the two AGR absorber lifts critical to the company being awarded the contract. With the single boom 1,600t capacity CC 8800-1 crane already on-site to carry out the smaller capacity lifts, the crane was then adapted to the SSL TWIN configuration by adding the second boom to lift the two AGR absorbers.

Once fully rigged in TWIN format, the self-propelled modular transports (SPMT) used to move the huge columns into position were also assembled. Each absorber was raised from the horizontal to the vertical using the CC 8800-1 TWIN crane as the main lift crane and using a tail frame to control the base of the absorber.

Once the crane had lifted the absorber clear of the SPMTs, the trailer was moved out of the way and the lift continued until the column was vertical. At this point the tail frame was removed, leaving the crane to carry the whole weight of the absorber.

The crane next slewed through 90 degrees and placed the column into its final position on the specially prepared foundation. The TWIN was then partially

de-rigged so that it could track a short distance into the correct position to carry out the second lift, and then be re-assembled to carry out the identical lift sequence with the second AGR absorber.

According to Al Jaber, the Demag CC 8800-1 and its TWIN version are “the best cranes”, not just the best for that job. “It was comfortable, easy to use, stable and flexible, and the operators were very happy with its precise and user-friendly controls,” says Al Jaber’s manager for the project.

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24

HARD HITTER JULY 2019

LOFTY PERCH

TOWER CRANE SPECIALIST WOLFFKRAN SHARES INSIGHTS INTO ITS MIDDLE EAST OPERATIONS, NEW DEVELOPMENTS AND PHILOSOPHY, AND HOW IT EMPHASISES PEOPLE AND LEARNING FOR GROWTH

Y

ou do not need to have exceptional observation skills to spot them – the slender, spiry, lattice-worked structures, reaching skywards as they stand next to the fastfilling skeletons of underconstruction towers, their tops crowned by long jibs of either the luffing kind or the straight sort, conspicuous in their trademark dull red paint.

Even with the ubiquity of tower cranes in the GCC region’s ever climbing skyline, Wolffkran units still stand out – not least because they can be seen on some of the most iconic projects in the region.

The German tower crane specialist has found great uptake in the region’s tower crane sector, says Mohamed Abou el Ezz, senior sales manager at Wolffkran IS’s Dubai office, which is responsible for the Middle East, North Africa and Southeast Asia.

“Over the past few years, we’ve seen considerable success in this region. We have our cranes at the biggest and the most iconic projects in Dubai and the UAE, and it’s the same in Saudi Arabia. In Dubai you can see our cranes building the Museum of the Future on Sheikh Zayed Road, whereas in Saudi we had 44 Wolff tower cranes on one of the Kingdom’s biggest and most important construction sites around the Masjid Al Haram in Makkah. Meanwhile, in Jeddah we have two Wolff 355B luffers climbing internally on the job-site of the highest tower in the world, while seven more are on the podium. So that’s a total of nine,” el Ezz tells CMME. “If you’re working on iconic projects where you have very strict deadlines and schedules, you don’t

25 Climbing up to a free-standing height of 90m with a load capacity of 60t and an 80m-long jib, the 1250 B Big Wolff luffer is one of the most important and capable cranes from Wolffkran.

“Through Wolffkran Arabia, we have a very special team… doing a fantastic job when it comes to service and maintenance, erection and dismantling – and this is making customers more interested to work with Wolffkran”

need a machine that continuously breaks down and has problems with service. So Wolffkran is a natural fit in such projects. Through Wolffkran Arabia, we have a very special team there, doing a fantastic job when it comes to service and maintenance, erection and dismantling, and this is making customers more interested to work with Wolffkran.”

He explains that Wolffkran operates in the region through partners. “In the UAE, we have the Kanoo Group as a partner and they are operating through a joint venture called Wolffkran Arabia. In Saudi Arabia, where the numbers of our cranes are higher owing to the larger market, we partner with the Roots Group. Our business model is to operate with partners, and we’ve been able to partner with some of the biggest names in the region.”

Having big regional houses as partners provides the synergies to go after prestigious and iconic projects such as the Museum of the Future in Dubai, an on-going build that comes with its own set of challenges.

“It’s a very special project and the challenges are not only maintaining uptime or providing service, but also smooth operation, because we are lifting and moving panels that are very expensive and delicate.

Any problem or miscalculation in positioning, or if you don’t have a smooth enough crane that is capable of operating and positioning the panels exactly as required, you are in a lot of trouble. Every panel costs a lot of money,” el Ezz explains.

“The contractor on the project is BAM International, who are among our global partners. They don’t just rent but they also purchase from us wherever they operate in the world, be it in Ireland, Germany, Australia or elsewhere.

“For this project, they required very special machines that can assist in remaining on top of strict deadlines. Low downtime, immediate support, very smooth operation were some of the most important requirements. In such projects, tower cranes are the bottlenecks – so if there’s any problem with the tower cranes, everything stops. BAM decided to proceed with us, and now there are three cranes working on the job there, two 355B luffers and an 8033 flat-top.”

On such projects, he adds, the emphasis is more on planning than on merely providing cranes. “The good thing is that Wolffkran is always there for supporting customers on the planning phase, and this is part of our strategy. And we do all specific technical consultation free of charge. Sometimes the project doesn’t end up with our machines, but we still use our expertise and share our knowledge when it comes to planning and special solutions, because we have a lot of special solutions to different projects as we gain experience from all over the world.

“This is the advantage of not just selling cranes but also operating a rental fleet, as Wolffkran does worldwide. You are increasing your knowledge as you gain experience from different projects; you are learning how to optimise your projects in order to provide the customer with what he needs. We make

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HARD HITTER JULY 2019

WOLF LINK

AS FAST AS A WOLF All Wolff tower cranes are equipped with Wolff Link, the company’s electronic crane management solution, says Mohamed Abou el Ezz. “The idea of the Wolff Link is to give online access to all crane data and operational information, to efficiently run your fleet or tackle crane maintenance issues. Faults or problems are detected with the Wolff Link and communicated to Wolffkran and the customer. Customers receive real-time alerts on any problem, its

diagnosis and solution.

“Our main service centre which receives the data is located in Germany. Very often the service centre itself can resolve the issue remotely through Wolff Link. If it cannot and there is a technical problem, the service centre directly communicates with our nearest warehouse, which sends technicians with the required spare parts to the site. If no spare parts are required, the service centre can directly send the nearest technician an alert so that he can go and

a plan for the cranes based on the loads, taking into consideration the positioning of the loads, whether there’s any logistical problems, what other machinery there is on the site, and many such factors.”

Another big Wolffkran project in the region is the ICD Brookfield Tower for Multiplex, one of the global customers with whom the tower crane specialist has a lot of projects worldwide. “That’s a really big project, a $1bn one. We have two 355Bs on it with approximately 300m tower height with

repair the crane on-site.”

Throughout the process, the customer is also kept in the loop and information is shared across the board. The point is to reduce the lead time by trying to diagnose the problem and find a solution before sending someone to the site.

“The whole issue we are talking about here is how we can minimise downtime and ensure our cranes are not sitting idle, but always doing what our customers want them to do – lift.”

a 50m jib. Wolff cranes are also building the Silicon Oasis Mall, on which we have one 8033 and five 7532 cranes. At the One Zabeel Tower project – which will have a road running through it – we have two 180Bs and one 244B.” As can be gleaned from Wolffkran’s motto at Bauma – ‘Wolffkran More’ – the company is not just a tower crane manufacturer but an operator and rental fleet owner as well.

“This means we’re not just manufacturing and selling cranes; we also have one of the

Wolffkran operates its own rental fleet of more than 800 cranes globally, and its towers are regular sights at several key projects in the Middle East, especially in the UAE and Saudi Arabia.

biggest rental fleets in the world, with 800 machines operating on all continents. Part of our expertise is not just manufacturing the machine but also operating it efficiently, and this also helps us develop our technologies and improve service, maintenance and operation, not just as a supplier but as a user,” el Ezz says.

Aiming for the highest levels of uptime and customer satisfaction while being both a seller and rental fleet operator, Wolffkran needs to be on top of the maintenance and

27 service game. El Ezz says the company has several strategies for that. One is swift onsite mobile service, which the company emphasised at Bauma.

“We presented our service vehicle at Bauma, which we consider our standard vehicle that you can find with the same components as we saw at the fair in all places that we operate, whether you go to Germany, the UAE or the USA. The idea is to standardise service and to make sure that all the equipment required is available when our service team goes to a site, so it helps them to finish the work they need to do on time and to our stipulated quality standards.

“It’s not just having some tools and fooling around searching for the right parts – it has to be a very organised effort, otherwise you lose time and ultimately the customer. This is something Wolffkran feels very strongly about, and that’s why we thought it would be a good idea to display our service vehicle at Bauma so that everybody can see what’s inside and how it’s presented.”

While having well-equipped, quickresponse vehicles is important, it is equally vital to have appropriately trained technicians manning them. This is another area where Wolffkran’s approach is meticulous.

“We have our central training centre in Germany where we offer different types and levels of training certificates. We also bring our trainers here regularly for local groups in, say, Saudi or the UAE, because of the obvious logistical ease of that. And the good thing is we already have our cranes here in every country, so it’s not difficult to troubleshoot

and train on the machine because it’s not just theoretical, it’s practical too.

“We have a three-level qualification for our technicians, and you have to clear all of them to be a certified Wolff technician. You have to continue training and get certified, after which there are annual refresher courses on the new technologies and developments.

This is also done for other teams like sales and management, to update them on the final products, on new technologies and what’s coming.”

To minimise downtime for end users, all Wolffkran partners across the globe operate the same standardised mobile service van, stocked with tools and parts for quick and effective on-site service.

And it’s not just technicians and training – Wolffkran also pays special attention to operators of its cranes. Nowhere is this better illustrated than in the Lifting Lounge.

El Ezz explains that the concept behind this is to develop it into a shared platform for Wolffkran’s operators.

“We really believe in the importance of crane operators. They play important roles in the decision-making of tower crane purchases, because based on their feedback there is an opportunity for us to improve operation and for customers to understand what makes the Wolff brand very special.

“Crane operators are required to answer some questions to get membership of the Lounge, and then they can operate our 1250 model virtually, sitting in a simulated environment of the crane’s application. But the operations are all very realistic: you have to move loads from one place to another and in a certain amount of time. We ran a competition, and the crane operator who took the least time gets to fly to the CONEXPO exhibition next year.

“The Lifting Lounge is also a platform where operators can share experiences. It is being developed into a new virtual platform, not just for operators but also for us as a manufacturer to get feedback and learn. The whole concept is how to gather information and transform it into usable knowledge. The idea is to make it a social media platform or a portal for our crane operators. They have a lot of experience that we as manufacturers can really learn from,” says el Ezz.

WOLFFKRAN AT BAUMA

UNLEASHING THE PACK At Bauma, Wolffkran introduced three main cranes – the 133 B hydraulic luffer, the 6020 flat-top or clear crane, and the Big Wolff 1250 B. “What’s special about the 1250 B is that it is a very heavy machine that can free-stand at 90m, has a load capacity of 60t and an 80m jib.

This makes it a very special machine. And it’s greatly optimised for assembly and support in terms of design compared to our competitors,” says

Mohamed Abou el Ezz. “When you compare the time taken to erect the 1250 B with any other tower crane, it will be less than half. When you see the machine and compare it to smaller models, you find that it doesn’t look as big as its actual size. The 1250 B is a simple crane, easy to maintain and operate, and this makes it special.”

Wolffkran has designed two versions for the 133 B. The 133.6 B has a maximum lifting capacity of 6.2t and a tip load

capacity of 2.6t with a maximum jib radius of 45m. The 133.8 B is an 8t version with a tip load capacity of 2.3t, for customers who want a higher maximum lifting capacity. Both luffers can be operated in single or two-fall mode.

The 6020 is offered in the 6t 6020.6 version and the 8t 6020.8 version, with three different tower connections per version.

The first can lift 2t at the tip at a 60m jib radius, while the tip load capacity of the second is 1.8t.

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29

R E W O P RAW EED TO N U O Y G N I EVERY TH

KNOW

34

TOP 10: EAT TIPS TO B THE HEAT

30_NEW RELEASES

d ep men an Steps to ke e ealthy in th machines h at. summer he

The latest releases from the world of construction machinery.

36_CONCRETE PLAN New transit mixer products designed around Middle East users allow businesses to run better.

40_HIGHLY PUMPED Advances in mobile concrete pumps bring in more and better ways of delivering concrete.

44_BOBCAT FAMILY French family builds threedecade-old business with mini kit.

30

NEW RELEASES JULY 2019

BOBCAT LAUNCHES LOADER REMOTE CONTROL WHY GET IT? SIMPLE OPERATION WITH PLUG-AND-PLAY SYSTEM FOR JOYSTICK-EQUIPPED LOADERS

NEW SNORKEL ELECTRIC SCISSOR WHY GET IT? SCISSOR STACK STOWS ENTIRELY INSIDE CHASSIS, LOW STEPIN HEIGHT FOR SAFETY Powered access heavyweight Snorkel has launched its next generation of electric slab scissor lifts, on display at Bauma after having been previewed as concepts earlier at CONEXPO 2017.

In line with Snorkel’s anniversary year theme, ‘Celebrating 60 years of innovation’, the company says its S3019E pushes the boundaries of scissor lift design. Developed from the ground up

by Snorkel’s in-house engineering team, the S3019E features a patent-pending design that enables the scissor stack to stow entirely inside the chassis.

This sunken scissor stack provides a low step-in height for the operator, which improves ease of ingress and egress from the platform. It also results in a lower stowed machine height of just 1.76m, meaning it can be driven through standard doorways without the need for folding guardrails, and is already compliant with the ANSI A.92 standards which come into effect in December.

New for Snorkel scissor lifts, the S3019E is equipped with both electric drive and electric steer, meaning there are no hydraulic hoses. This eliminates the risk of hydraulic leaks, making the lift ideal

for use in sensitive areas, and improves the duty cycle, as there is less energy loss compared to hydraulic driven units.

The Snorkel S3019E can lift up to 250kg to a maximum platform height of 5.79m.

Just 0.77m wide, the S3019E is equipped with a 0.91m roll-out extension deck that expands the maximum working area to 0.61m x 2.6m. Weighing 1,581kg, the battery-powered S3019E has nonmarking tyres as standard, and is rated for one person plus tools for outdoor use.

Snorkel CEO Matthew Elvin says: “We believe that the Snorkel S3019E will disrupt the standard convention of what a slab scissor lift is. In terms of safety, the low step-in height is a major benefit, as a large proportion of job-site accidents occur when operators are entering and exiting the working platform. From a productivity standpoint, the overall low stowed height eliminates the need to fold down guardrails, and the electric drive and electric steering provide a long duty cycle and zero inside turning radius, for greater manoeuvrability on the job.”

Shown as a pre-production unit at Bauma, both ANSI- and CEcompliant versions are now available to order, with the model expected to enter US production in Q4 2019.

SPECIFICATIONS

SNORKEL S3019E Max height: 5.79m Max lifting capacity: 250kg Total unit weight: 1,581kg Drive: Battery-powered

Bobcat has announced a new remote control system for its compact loaders, allowing operators to leave their seat in the cab and control their Bobcat loader remotely. The remote control is compatible with Bobcat’s skid-steer, compact track and all-wheel steer loader models equipped with the company’s selectable joystick controls.

The company said this makes it the first manufacturer to introduce a remote control system as original plug-and-play equipment, rather than as an add-on development from a third party. The new system will be commercially available later this year.

According to Bobcat, remote control solutions have proved their qualities and abilities to save lives in the toughest environments all around the world by providing service during disasters like floods, forest fires, mud and rockslides, and in other places where operators can be subjected to dangerous situations.

“We first presented our remote control prototype at Bobcat Demo Days, with excellent feedback from our customers, then subjected it to further improvements, testing and licensing, before finally introducing it as an easy plug-and-play solution for existing machines for commercial launch,” said Jiri Karmazin, loaders product manager, Doosan Bobcat EMEA. The system is an easily portable and industrial radio remote control solution that can be mounted and dismounted on machines in minutes.

31

CAT LAUNCHES NEW UNDERGROUND LOADER WHY GET IT? ENHANCED COOLING, EXPANDED EMISSION CONTROL AND EASE OF SERVICE The new Cat R2900 underground loader offers configurations to meet the strictest diesel engine emissions standards and continues to deliver the high performance and 17.2t payload of its predecessor. It is powered by the Cat C15 engine, available in a number of emissions configurations to meet the needs of mining operations around the world.

The six-cylinder engine is turbocharged and air-to-air after-cooled, producing 409hp in standard configuration and 393hp in EU Stage V compliant form.

The machine is available with high ambient cooling capability. The key component is a high-efficiency radiator featuring a modular design with individual tubes that can be serviced independently to reduce maintenance time. The radiator also is resistant to clogging and allows faster cleaning and longer service intervals.

The engine end frame design features simple new structures that extend durability and accommodate modular components, which facilitate maintenance and repair. Remote axle and transmission coolers and filters enable easy access, and a single fuel tank replaces the dual tanks on the previous model. The new tank provides ground level access for refuelling.

The available brake release and tow hook allow the parking brake to be disengaged and hooked to the machine from the rear, if the machine must be towed.

The in-cab display enables machine health monitoring through Cat Product Link Elite.

The new system makes it easier

to share data across multiple destinations.

Scalable remote operation technology starts with the Cat line-of-sight console.

Critical machine information is now presented on a display in the console.

Additional MineStar Command technology enables teleremote and semi-autonomous operation from a distant operator station.

A range of bucket sizes and configurations are available for the R2900, to match material characteristics and optimise productivity. With the introduction of Bolt-On Half Arrow ground engaging tools (GET) for bucket edges, Caterpillar now offers a complete range of Cat GET and bucket wear solutions for underground loaders, to optimise the system for the application.

With a proven and reliable retention system, the bolt-on GET offer more wear material than standard weld-on GET, and the bolt-on design enables fast and easy removal and replacement. Despite additional wear material, the lowprofile front edge eases pile penetration and promotes fast bucket loading.

SPECIFICATIONS

CAT R2900 Max payload: 17.2t Engine: 6-cylinder Cat C15 Engine power: 409hp GET types: Bolt-on

32

NEW RELEASES JULY 2019

JCB DEBUTS SUB-COMPACT TELEHANDLER WHY GET IT? IDEAL FOR CONFINED JOB-SITES IN MAINTENANCE, CLEAN-UP AND MATERIAL HANDLING APPLICATIONS

NEW MAMMOET 18,000T LIFTER WHY GET IT? AN INDISPENSABLE SOLUTION FOR SUPER HEAVY LIFTING PROJECTS Heavy lift and move specialist Mammoet has announced the introduction of a new crane concept with a lifting capacity of 18,000 metric tonnes. The Dutch multinational said the new MSG1000 concept model derives from its successful fleet of ring cranes, the MSG80 and PTC ranges. According to Mammoet, the ringer crane concept has revolutionised efficiency in both construction and maintenance work across heavy industries, which need to operate on ever larger scales as production sites become more complex and congested.

The Mammoet Sliding Gantry (MSG) and its range of PTC cranes combine extreme lifting capacities of up to 5,000t with exceptionally long reaches of up to 256m. Combined with a small footprint and 360-degree versatility, Mammoet says, these cranes have proved their worth in the last decade in dozens of projects around the world with a need for high capacity in congested or confined areas. Mammoet currently operates ten PTCs worldwide.

Jacques Stoof, Mammoet global director, Market Development and Innovation, says: “The MSG80 and PTC cranes have revolutionised construction and maintenance efficiency in the last decade. However, we see from developments in, for example, modular construction, there is a growing need for cranes with significantly more lifting capacity than the market has seen thus far.

While we have left the basic concept of the PTC intact, we have enhanced its capacity.

Among other features, a double boom and strand jacks in combination with winchesbased hoisting significantly increases its capacity – up to 18,000 metric tonnes.”

To cater to growing demand in the sub-2.7t category, JCB has introduced a new telescopic handler – the 504-13 Loadall sub-compact. According to the manufacturer, demand for this particular weight class of telehandlers is growing fast, especially in North America.

The new JCB 504-13 telehandler is capable of lifting a maximum weight of 1.8t and has a maximum lift height of 4m.

It is suitable for maintenance applications, job-site clean-up and material handling within confined work-sites. Building on the design and capability characteristics of JCB’s earlier 520-40 Loadall telehandler, it is powered by a new 39hp Perkins diesel engine which is Tier 4 Final-compliant.

Rebecca Yates, product manager for JCB North America, says: “JCB is the biggest selling telehandler brand in North America and around the world. Much of our success especially extends from our popular early compact telehandlers. And with the compact telehandler market up

by about 30% this year, it’s an exciting time to add a new sub-compact machine to the JCB line-up and further extend the most diverse telehandler range in the industry.”

Among other features, the new JCB 504-13 telehandler sports an all-steel bodywork, permanent four-wheel steering for enhanced manoeuvrability, low boom profile for exceptional visibility for improved productivity and safety, compact tool carrier or skid-steer coupler for attachments to accommodate a wide array of applications, twospeed hydrostatic transmission, and a two-year/2,000-hour warranty.

The 504-13 Loadall features JCB’s unique U-pressed steel boom with fewer welds and stress points than other brands, says the company. Also unique to JCB Loadall telehandlers are 500-hour extended service intervals and simplified maintenance procedures, with all daily checks performed at ground level.

Introduced as a Tier 4 Final machine, the 504-13 Loadall is available in the North American market at present.

SPECIFICATIONS

JCB 504-13 LOADALL Max lift height: 4m Max lifting capacity: 1.8t Engine power: 39hp Transmission: Two-speed hydrostatic

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34

TOP TEN JULY 2019

02

01 MEETINGS SET THE TONE Keep your staff prepared to deal with the conditions, and reinforce the message of being aware of the effects of the heat and heat exhaustion, with a meeting before every shift. Use the meeting to outline safety plans and remind the team of site conditions and potential hazards.

FREQUENT BREAKS Once work has begun, make sure operators have frequent breaks and take in enough fluids to restore their energy. The searing summer heat of the region is energy-sapping, and fatigue can lead to slower work and being prone to mistakes that put men and machines in danger.

: N E T P TO T A E B O WAYS T T A E H R E M M U S THE

S IN GOOD E N I H C A N AND M E M P E E MMER K U O S T H S S P R E A T S ION’S H G E R E H T ORDER IN

03

PROPER STORAGE Store any equipment not being used during the summer indoors or in a shaded area, covered and protected from the elements.

Leaving it out in the yard will lead to potentially disastrous sand accumulation in critical components such as hydraulics and fluids.

USE MORE ES men MACHIN , replace

ossible Wherever p er new s or consid e in h c a m e control with ons, machin tactics. ti p o t n e m attach r-saving other labou at much devices or ithstand he w n a c s e in still be Mach orkers and w n a th r e tt be lly more ile it’s usua h W t. n ie c effi workers to employ e v ti c e ff -e cost n, make an in our regio r the exception fo summer.

04

35

05

06

THE RIGHT KIT The Middle East summer is among the harshest working environments in the world, and not all manufacturers take this into account when producing their models for the world market. Stick to kit from tried and tested top brands which customise their machines for the region’s conditions.

CHECK FLUIDS Top up your machines with the recommended grade of coolant.

Ensure there are no leaks in the cooling system and other fluid lines by checking the coolant lines, seals and hoses. Also make use of strip tests to ensure the coolant has not been adulterated with other liquids.

07

TYRE CHECKs expands

e tyre The air insid and ratures rise e when temp tyre n o pressure overexerts more se u a c re can u ss re p is h T g serious walls. urst, causin b to s re ty pressure inflated onitor tyre m so , ts n e accid o wears . Rubber als ck more often mer, so che faster in sum ion more dit the tyre con nd change a y tl frequen if worn out.

09

08

AIR-CONDITIONED CABS In the summer heat, machines with airconditioned cabs are a must, not a luxury. To maximise operator productivity, use equipment with cabs that are air-conditioned and designed for ergonomic comfort. Also ensure AC systems are properly serviced before summer starts.

MAINTAIN PROPERLY Machines are more prone to failure during the summer months, due to the stress of operating in hot conditions. To prevent failures, ensure your machines are looked after and take extra care to stick to the correct maintenance schedules.

10 ABIDE BY HEAT LAWS Midday breaks are mandatory by law in GCC countries, as is stoppage of work once the mercury hits a certain level. Stick to these rules, not only for the safety of your staff but also to avoid heavy fines.

36

COVER STORY JULY 2019

Liebherr’s new HTM 1304 transit mixture, which is only offered on a 48t truck chassis, is a new approach to transporting concrete, raising water volume while reducing spillage.

“Now, for 12m3 of concrete, even if you are at a slump of 240mm, which is pretty liquid, you are fine. The mixer will not spill and you can drive it easily, climb up inclines, flyovers and bridges, and go around corners and roundabouts - all without any spillage, as tested”

37

CONCRETE PLAN

WITH NEW MODELS, SUCH AS LIEBHERR’S HTM 1304, TRANSIT MIXER MAKERS ARE PUTTING OUT PRODUCTS DESIGNED AROUND MAKING THE MIDDLE EASTERN USER’S BUSINESS MORE PROFITABLE

I

t may not be the first realisation that comes to people’s minds when they think about the concrete sector, but if you’re in the concrete business, you’re actually in the transport business. As much importance as the product – the ready-to-pour grey stuff – has for the sector, when it comes to operations, it’s all about transporting the mix to where it’s required.

This is one obvious yet often glossed over point that Ali Kassem, regional sales manager, Middle East, at Leibherr’s Concrete Technology Division emphasises to CMME while discussing an innovative new model that Liebherr has introduced in the region – the HTM 1304 transit mixer.

“The HTM 1304 is basically for liquid concrete. For a while now we’ve noticed that more and more liquid concrete is being used in the market. The slumps are high and it’s all about pumpable and fluid concrete, so that it’s easy to apply and easy to pump to high levels. As concrete gets more liquid, there is a greater tendency to spill on the road while in transit, because of the design factors of the 12 cubic metre truck mixers, such as the Liebherr HTM 1204, which are the overwhelming favourites in most of the GCC,” Kassem says.

“There is a relation between the slump and the viscosity of the concrete, and the mixer has to take that not account. Most of the 12m3 mixers usually have a lower angle than smaller mixers because of their size and design, and because the length of the truck body places some design constraints. And this is why you notice that most 12m3 mixers slant a little downwards rather than pointing upwards at a higher angle.

“Of course, there are solutions for this. You can fit a gate for the mixer, but that is not a preferred option in the Middle East as it also has an additional cost. Also, the gate has to be to kept clean and maintained, and that also adds to the costs. Maintenance is always an issue in our market, and a driver looking after his truck mixer is always rare. So, if we want to add more

complicated things onto the mixer, it not only means more maintenance but also demands more training for the driver and more attention and commitment from him, which may not be coming.

“The easier way is to redesign the drum itself so that it will take a little bit more water volume, so that we can avoid spillage on the road without having a gate or cover at the end of the mixer. This was the whole idea behind our 1304’s design.”

Kassem also notes that with the liquid concrete, a 12m3 mixer needs to be filled to the 11-11.5m3 mark, depending on the slump, which does not go down well with customers.

“Customers then come back and say they are losing a cubic metre or so per trip, and since they have so many trips per day and so much concrete to deliver per month, it is a big loss when seen cumulatively compared to what they can do if they fill 12m3. This is because they calculate the cost of transport, which is their main expenditure. And it is sometimes ignored that transport is at the heart of the concrete business.

So here the cost is really killing for them.”

In light of all this, Liebherr thought about what it takes to fill 12m3 of a 230 or 240mm slump into the mixer. Then they redesigned the mixer and pedestals accordingly, and raised the angle of the drum a little.

“We did some tests with the our old 1204 model and with an enhanced version of it. These tests were done in the UAE with an established ready-mix company, and the conclusions proved that if the drum angle is raised by a certain value and some extra plates or capacity sheets added inside the drum, gaining a certain amount of volume was possible. Once we had the results and we knew what to improve and how, Liebherr redesigned the mixer and when we tested it, we reached a volume of 13.6m3,” Kassem points out.

“Now, for 12m3 of concrete, even if you are at a slump of 240mm, which is pretty liquid, you are fine.

The mixer will not spill and you can drive it easily, climb up inclines, flyovers and bridges, and go around

38

COVER STORY JULY 2019

“Together, CIFA’s Energya and the Scania gas truck form the most innovative model of the hybrid mixer, reducing fuel consumption by 30% and CO2 emissions by 95%“ corners and roundabouts easily - all without any spillage, as tested.”

Though Liebherr calls it the 1304, in effect the model is actually a 1204 with a higher water volume - or “a 1204 that can now be loaded all the way to the 12m3 mark”, Kassem points out.

“This gives our customers that one to oneand-a-half cubic metres of capacity per trip that they were unable to utilise on the 1204 model. We thought about naming this model 1204-plus, but then we decided we needed to tell end-users that this is a different product and at least has a higher water volume capacity, so

Green solutions to transporting concrete are high on CIFA’s agenda, with the Zoomlion-owned Italian concrete equipment major developing hybrid mixers.

we differentiated it by its name. We are keeping a safety margin when loading the concrete while at the same time telling customers that the little bit in capacity that they lost out on with the 1204 can now be filled up. Also, with the 1304, we can now cover a lot of ranges of concrete products in terms of supply, because concrete is just not the same always - there are a lot of ranges depending on the mix design.”

However, the redesign has led to one major change – the truck chassis. Whereas the 1204 was built on a 44t chassis, the 1304 only comes on a heavier bed, and Kassem explains: “We

STETTER’S LANDMARK

111,000TH TRUCK-MIXER AT BAUMA At Bauma 2019, Stetter showed off its 111,000th truck mixer model with a special paint finish to mark the anniversary.

Stetter, part of the German equipment specialist group, Schwing-Stetter, has been building truck mixers in Memmingen, Bavaria, for around 60 years, and for many years also at various company locations worldwide. India plays a special role, where Stetter truck-mixers recently had a market share of over 80%.

Stetter says its truck mixers are designed for efficiency, performance and economy. The best example of the success of the truck mixers is the UltraEco model. With a weight of only 3.2t, the UltraEco is Stetter’s lightest truck-mixer superstructure and is combined with a weight-optimised chassis for a payload of eight cubic metres of fresh concrete.

UltraEco fleets are optimally utilised in combination with a Stetter mixing plant with the new twin-shaft mixer DW 4.0,

says the company. With two batches, the maximum loading capacity of 8m³ is achieved exactly and the unproductive service life of the truck-mixer is reduced. The high capacity combined with renowned robustness and long service life are what make this truck-mixer concept successful and have made the UltraEco a benchmark for lightweight truck-mixers everywhere.

The UltraEco alone has been sold over 3,000 times since its market launch in January 2015, said Stetter.

are only building the 1304 on the 48t chassis rather than the more common 44t chassis that our 1204 and our competing brands are based on. This is because providing the 1304 only on a 48t chassis is not only better for the chassis but also for the mixer and better overall for the customer in terms of safety and durability.”

Beyond this important new introduction, which replaces the 1204 model, Liebherr still has its smaller mixers. “We have mixers in lots of capacity ranges, such as the 10, 9 and 8 cubic metres and more. But now the 1304 has replaced the 1204. While Mercedes is the

39

INTELLIGENT MONITORING

USING THE CLOUD American company GCP Applied Technologies’ Verifi In-transit Concrete Management system uses sensors installed on readymix trucks to measure, manage and record concrete properties in transit. Using cloud-based technology, Verifi customers are able to connect with real-time data to monitor and improve the quality and performance of concrete, increase productivity and accelerate job completion.

The system has been available since 2010 and now GCP has acquired Canada’s SensoCrete, whose technology it intends to use in the existing Verifi system to

usual chassis for Liebherr mixers by tradition, we can sell our mixers on any chassis, as per customers’ requirements. We have good relations with almost all chassis suppliers, such as Volvo, MAN, Scania and Iveco.”

Meanwhile, Stetter, another German company and part of concrete equipment specialist Schwing-Stetter, showed off a new technology for mixers at Bauma with its AM 10 EDrive. The mixing drum of the AM 10 EDrive can be driven either hydraulically via the vehicle engine or electrically via the batteryoperated electric motor.

Both the hydraulic and electric motors use the same gearbox to transmit the drive forces to the mixing drum, but in different situations.

While the drum is driven hydraulically via the auxiliary drive of the diesel engine when driving to the construction site as usual, the electric motor takes over when loading in the batching plant and during unloading on the job-site. The emission load at the loading and unloading by the truck-mixer is eliminated. In addition, the electric drive can be optimally used for emission-free maintenance work, for example in closed halls and workshops.

The battery is charged via a standard power connection (230V). The drive was developed by Dutch specialist Wierda Hybrid Technologies.

The system’s additional weight is just 475kg, equuivalent to less than 1/5m³ of concrete.

Green technology also receives importance at Italian concrete equipment major CIFA, as does the transport side of things with the truck body, says Wajih Eit, GM, Zoomlion Gulf, the owners of the CIFA brand.

“The business of mixers is directly connected

to the business of trucks; even the requirement of the end user is based on the truck. He wants a certain brand of truck based on his fleet.

Since it’s directly related to the truck, normally our Italian mixers are mounted on European trucks - Mercedes, Volvo, etc. - because these suppliers send their trucks to our facilities, where we mount the mixers and send it to the market. Our made-in-China mixers are mounted on Chinese-made trucks, because to transport European chassis all the way to China would push up costs frightfully,” Eit says.

“We have a specific mixer product for the Middle East and we call it the HD 1. HD is

extend the number and type of concrete properties measured, offering ready-mix customers a greater range of data and more commercial advantages.

Already operational in the US, GCP Technologies now intends to expand the reach of its Verifi systems. “Global expansion of the Verifi system is currently underway,” says Laith Haboubi.

“The positive feedback we have received from the Middle East would indicate a strong need for intelligent monitoring and management systems in the regional ready-mix concrete industry. We have presented to several customers who have all

The concrete business is a transport business at heart, say specialists in the sector, and the choice of truck chassis is a very important point for customers.

been very interested in pursuing the technology further. We will continue our sales process in the Middle East, leading to our first customer in that market.”

Describing the Verifi InTransit Concrete Management system as an “innovative technology” and the “only one of its kind in the marketplace”, Haboubi explains that the system monitors, measures and manages concrete slump and other properties from batch plant to job-site.

“It provides visibility to data in real time to help producers and contractors consistently meet target concrete specifications.”

heavy duty, and this range of products were launched around 2012-13 specifically for the Middle East and Africa. Since the launch, we can confidently say that this is the best mixer in the market. It has a reinforced structure and the thickness of the drum is at 7mm - higher than all our competitors. We have 2+2 rollers, four in total, on which the drum is running.

Our 12m3 mixer has a 1200l water drum as standard. This heavy-duty mixer is dedicated for the Middle East.”

CIFA has noticed that in some parts of the region, such as Saudi Arabia or Kuwait, the roads can be difficult, especially where the ready-mix companies are located. Also, the drivers can be a bit aggressive, whereas a transit mixer of more than 40t is something that should be driven like a car on the road. “So, there were some structural problems on the truck itself in the past. But when we launched this range of mixers, we also eliminated the problems on the truck,” Eit says.

Turning to new introductions at Bauma he reveals that two models of CIFA’s Energya E9 hybrid mixer mounted on Scania G410 trucks were on display at the event.

“Together, CIFA’s Energya and the Scania gas truck form the most innovative model of the hybrid mixer, reducing fuel consumption by 30% and CO2 emissions by 95%, with noise reduction on both the truck engine and the drum - all without compromising performance.

A combination of two as yet unparalleled technologies - the biomethane gas engine truck and the electric motor of CIFA Energya - allows concrete to be transported more economically and with greater environmental benefits.”

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CONCRETE PUMPS JULY 2019

HIGHLY PUMPED

CONSTANT TECHNOLOGICAL ADVANCEMENT IS ALLOWING THE MOBILE CONCRETE PUMPS SEGMENT TO BRING IN MORE REACH, POWER, SAFETY AND INNOVATIVE NEW WAYS OF DELIVERING CONCRETE

A

mong the defining characteristics of the Middle East construction sector is the penchant to build tall. The support structure of this activity is concrete, and the truck-mounted concrete pump is one of the most important pieces of kit in the region. And reaching new heights seems to be the name of the game.

For concrete equipment specialist, Cifa, that’s no problem. The Italian manufacturer is well known for its range of long-boom pump trucks, says Wajih Eit, the company’s head of area for the Middle East and North Africa. Cifa has a three-pronged range of pump trucks - Carbotech, Steeltech and Classic - he tells CMME, the first of which has models that hold the record for the longest booms in the world.

“Our Carbotech series of truck pumps are made with a section of their booms fashioned out of carbon fibre, a technology that Cifa has developed and patented. This reduces the weight of the boom, and the truck as a whole, by more than 25%, which means that the truck can have a lower axle weight per axle. This, in turn, means that with the Carbotech system we can mount pumps with higher booms on trucks that are lighter than they would otherwise be, enabling them to meet axle weight restrictions on the roads and reach more job sites.”

As an example of the capabilities the

Carbotech system brings to Cifa, he reveals that the biggest pump that Cifa can mount on an 8X4 truck today has a a 60m carbon fibre boom. “Our competitors can only mount a maximum of around a 55m boom on the same kind of truck,” Eit point out.

“The Carbotech line is the most advanced one for us now and is doing great in Europe. It is surely the future for the Middle East. We’ve supplied a 60m Carbotech in KSA, and also in Algeria. We will soon supply a third unit in Qatar and we’re also negotiating for other units in the UAE and other countries.”

Thanks to this technology, Cifa today has the biggest pumps ever to be completely mounted on trucks – “like our 80m and 100m”, says Eit. “The 100m pump is already working in the Chinese market. We cannot use it yet in the ME or Europe because of the axle weight regulations on the roads here.

The biggest that can work in this region is the 80m, as per the current regulations. We are in negotiations for several of these in the region, which will enter this market in the next two years.

“In the Carbotech, we have no competitors at the moment, and that’s because this technology was invented by Cifa and we have the patent for it, which gives us exclusive production rights for 10 years.

There are still six more years to run on that patent and for that time we will be the only company offering this technology.”

Moving on to the Steeltech, Eit says that it is the company’s standard normal pump in the market. “Like the Carbotech, it is 100% made in Italy. We launched several new

41 CIFA offers an extensive line-up of truck-mounted conrete pumps in the carbotech, steeltech and classic ranges to suit a variety of customer preferences.

“Our Carbotech series of truck pumps are made with a section of their booms fashioned out of carbon fibre, a technology that Cifa has developed and patented. This reduces the weight of the boom, and the truck as a whole, by more than 25%, which… means that we can mount pumps with higher booms on lighter trucks”

42

CONCRETE PUMPS JULY 2019

products in this range recently, such as the 42m and 55m, with which we are doing great numbers in the region today, thanks to the tech we are putting inside – such as the open circuit of the pumping unit, the high performance of the fast-moving parts inside it, plus the low cost of maintenance.

“The Classic is the new series we launched a year ago for some selected markets, but from this year on we will be bringing it to the Middle East as well. It is designed by Cifa in our design centre in Italy and has Cifa technology, but it is made in China in our dedicated factory there. So it has great performance and all the characteristics of our brand, but it competes on a value proposition against the Chinese and Korean manufacturers on the market.”

Meanwhile, at another European manufacturer, Leibherr, its exclusive XXT outrigger system is an innovation that provides specific advantages for everyday applications on building sites. With the narrow support option, the front outriggers can be extended up to the front of the vehicle, allowing a greater working range of up to 70%. This also enables pumping concrete over the operator’s cab, which is a distinct advantage.

Other advantages include direct power

Liebherr’s XXT outrigger system enables the truck outriggers to be opened at very acute angles to enable pumping concrete over the cab of the truck for flexible usage.

transmission from boom to outrigger. Also, the XXT design ensures that no forces are directed towards the vehicle frame/chassis by the distributor boom.

With only a simple telescoping of the front outrigger, the truck is ready to pump. The front and rear support rotate around the same centre of rotation or pivot, providing optimum possibilities for narrow support and flexible set-up angles. The design also reduces the vehicles overall weight by eliminating the entire fulcrum for a separate front outrigger.

Stability is also enhanced by the XXT design, as is working over the roof of the operator’s cab even with the narrow support option.

“In the XXT, we actually have the front outrigger sitting inside the rear one. So when you close the outriggers, the front leg closes into the rear one, which is made of two long pieces with a hollow space towards the base.

This is also an advantage because then you have less deflection and less vibration,” says Liebherr’s Ali Kasem.

“It also gives a lot of flexibility, because you can open it at a very small angle and you don’t need to open at a full angle. You can also move it wherever you want. Let’s say there is an obstacle and you cannot open the outriggers fully and you can just open one a little bit. In such a situation in the XXT, if you can open one, the other will come out of it and form an acute angle from the same pivot - and you are set to pump.

“This is really an advantage for work in congested areas where you cannot open outriggers fully, or you can only open them a short distance. With the XXT, you are still at full extension but you are at a smaller angle, which still makes you stable.”

“Pumps is a new business for Leibherr,” he says. “We came into this category when Liebherr acquired German pump specialist

SCHWING S 36 X DIRECTDRIVE

A 360-DEGREE REVOLUTION FOR TRUCK PUMPS With the DirectDrive, Schwing is revolutionising working with truckmounted concrete pumps. The innovative drive not only combines the specific advantages of the previously known boom folding types of a machine, but also creates completely new application possibilities. The S 36 X DirectDrive can therefore be used more flexibly than any other truck-mounted concrete pump in its class. The S 36 X DirectDrive from Schwing is a masterpiece.

With the DirectDrive, the Schwing engineers have achieved a technical

masterpiece. The third boom stage of the S 36 X DirectDrive provides a remarkable opening angle of 330°, while the last boom stage can be continuously rotated a full 360°. The idea for the limitless mobility of one or more boom joints was developed by SCHWING engineers in St. Stefan, Austria. This is where the basic idea for a rotary motor drive in the boom joint was developed, which is operated with the

aid of gear technology.

The DirectDrive eliminates almost all restrictions at the last two boom knuckles that arise from the use of hydraulic cylinders. The DirectDrive, with its unique flexibility, also eliminates the need for the classic boom folding types R, RZ or Z. The entire handling and thinking involved in operating a truckmounted concrete pump, all movements in halls and threading into buildings

have reached a new, revolutionary stage. Thanks to the direct control of the DirectDrive hydraulic motors, the operator’s control commands are immediately translated into movements, for the boom of the S 36 X DirectDrive to be moved extremely sensitively and precisely.

The DirectDrive shows Schwing-Stetter’s special in-depth manufacturing.

All relevant components and developments were

developed, programmed, tested and manufactured in Herne and St. Stefan. The S 36 X DirectDrive naturally also uses the well-known and proven SCHWING components that make the machine in combination with all its features an exceptional model.

43

Waitzinger some six years ago. Our range consists of the 37, 43, 47 and 50m models, all XXT. Of these, the 43m is probably has the most consistent demand.”

Another illustrious name in the sector is Germany’s Putzmeister. Also under Chinese ownership – of Sany’s to be precise – it is one of the most popular brands of concrete pumps in the region and has to its credit many projects of global renown to which it has supplied pumps – such as the iconic Burj Al Arab and Burj Khalifa in Dubai.

Speaking about the market Paul Bruns, head of Putzmeister in the Middle East, says: “It’s still tough, we have still the case that the supply on the ground for machinery is exceeding demand. Of course, we have different markets so Kuwait is not UAE, UAE is not Saudi. I see that the volumes that we had in 2013-2015 will most likely not come back. Nevertheless, I see that there is potential, especially in Saudi Arabia with the agenda 2030 and also in the UAE benefits Expo 2020 and other with the upcoming

Using its Direct Drive technology, Schwing launched truck mounted pumps at Bauma whose booms can rotate 360-degrees for easier delivery of concrete in tight spaces.

construction projects in the region.

“We have together with our partners developed a value proposition including a fantastic service network here in the 40 years we have been in the region, so with that experience and people on the ground we are able to offer long term savings for the industry and I think this might be more in demand also in the future.

“Putzmeister in general is the only manufacturer who invested 25 million Euro in a testing facility where we are testing each and every component up to a lifetime of 10 years. So, considering this, we are sure that in the long run we are the cheapest.

The initial cost might be high, but the long term total cost of ownership of Putzmeister is still the best. We are the only one who has adjusted the scope of supply to the local refinements. So, we have specifications built in our machines which are only made for the GCC market.”

These specifications, he explains, pertain to the cooling, reliability, safety and performance of the pumps. “Our dealer network has to do a boom inspection of every pump on an annual basis. This is a mandatory requirement, whether the customer has asked for it or not. So this increases the reliability and safety of Putzmeister pumps.”

MASTER PUMPER

NEW ILS PUMPS FROM PUTZMEISTER At Bauma 2019 Putzmeister showcased its new generation of iLS truck-mounted concrete pumps with higher safety standards, more power and reduced operating costs. The machines come with a range of features, including the Ergonic 2.0 control system and a new hydraulic system.

According to Putzmeister, the new ILS pumps are more durable than any other pumps

on the market. The secret to the success of the previous HLS generation – reducing wear using larger cylinder diameters and fewer strokes – has been refined and perfected by the company.

This results in a significant increase in power due to a number of factors, including the prevention of leaks and approximately 10% better suction performance, which results in improved concrete

flow and innovative control.

In combination with the newly designed Ergonic 2.0 control system, this saves up to 25% more fuel.

The Ergonic 2.0 controls supports the operator to make their machines ready for use quickly while generating less wear and saving fuel. This involves the use of a range of modules, depending on the application.

“Controlling the optimum

engine speed and a newly developed hydraulic management makes it possible to achieve fuel savings of up to 25%. This guarantees that the concrete pump operates smoothly, with low wear and high fuel efficiency,” says Markus Frasch, Putzmeister’s director, Product Management.

The new range boast the 36-4, 63-5 and 51-5 models.

The 36-4 offers optimum

accessibility and convenient operation with concepts such as the new lights that enable safe work even at dusk or in the dark. A new construction concept reduces boom vibrations and enables a more efficient and safer operation of the machine.

The new 63-5 is around 1t lighter than its predecessor, but its equally sturdy. The pumps boom is equipped with a DN 125 delivery line.

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THE LAST WORD JULY 2019

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Saudi Liebherr Company Ltd. P.O. Box 9972 Dammam 31429 K.S.A. Phone +966 (0) 13 831 4815 E-Mail: info.slc@liebherr.com www.facebook.com/LiebherrConstruction www.liebherr.com

Liebherr Middle East FZE P.O. Box 2540, Jebel Ali Free Zone Dubai / United Arab Emirates Phone: +971 4 8891 888 E-Mail: info.ldu@liebherr.com www.facebook.com/LiebherrConstruction www.liebherr.com