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Placing System Advantage

MORE THAN EQUIPMENT

© 2007 Putzmeister America, Inc. - All Rights Reserved. CP 3856 US

 PUTZMEISTER I NT ROD U C TI O N

Putzmeister High Profile Projects

MGM CityCenter – Las Vegas

Trump Tower – Chicago

Trump International Hotel & Tower – Las Vegas

One Rincon Hill – San Fransisco

JW Marriot – Michigan

Tacoma Narrows – Seattle

Central Library – Minneapolis

Brightman Street Bridge – Massachusetts

Columbus Towers – Chicago

Three Bellevue – Seattle

OHSU Biomedical – Portland

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PUTZMEISTER
I N TROD U C TION
SYSTEMS APPROACH

Step-by-Step Sequence Chart

Our specialists work with you from project start to finish
providing technical expertise in specifying equipment,
consulting on concrete mixes and designing an efficient
placing system for maximum concrete coverage.

Planning/Bidding Stage: 3

• Review advantages with the contractor, including

labor and time savings.
• Size the unit.
• Discuss location along with crane size to install and
remove unit.
• Discuss rental rates and all costs with the contractor.
• Include freight, taxes, setup costs and insurance.
Pre-Installation Planning:
• Check boom location – no obstruction of slab
opening for tower.
• Check pump location and layout of line, diversion
valve and blowout area.
• Ensure size of boom with proper reaction forces
given to the building’s engineer.
• Determine length of tower and support floors. 4

• Make a climbing plan showing support floors and

wedge points.
• Discuss how the unit will be climbed (with crane,
self-jack or freestanding).
• Determine if reshoring is necessary to support the
unit and check who will install.
Installation:
• Trucking and delivery.
• Crane scheduled.
• All equipment identified and on-site.
• Reshoring.
• Electrical power.
• Placing line route and fasteners.
• Slab opening and size checked.
5
• Location of vertical supports and horizontal wedges
or corner details.
• Tower bolts properly torqued, where applicable.
Operation:
• Continuously check connections (bolts, pins,
electrical and pipeline).
• Check radio remote.
• Continuously check wedges, supports and reshoring.
• Moving boom from mast to mast – check both towers.
• Watch pipeline life, including boom, tower and
supply line pipe.
Dismantle:
• Schedule trucks.
• Crane clearance for tower removal. Tower may
have to be dismantled.
• Removal of concrete piping.
• Fill in slab openings.
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 PUTZMEISTER
PLACING BOOM SYSTEM ON-SITE
I NT ROD U C TI O N

How to Lay Out Components

on a Job Site for Effective Use

For a typical project layout, consider the following:

• Traffic/lane restrictions.
• Mixer truck access.
• Straight forward line layout.
- Minimize elbows.
- Shortest distance.
• Multiple pour locations.
• Surge block locations.
• Clean out access.
Putzmeister can assist with all of these aspects.
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CUSTOMIZE
E D UC ATIO N
CREATE THE SYSTEM YOU NEED

FOUR STEPS TO PLACING BOOM SUCCESS

1. Choose Your Boom and Pedestal

2. Specify Pin or Bolt Towers

3. Define Your Mounting and

Climbing Configuration

4. Order Your System

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 CUSTOMIZE PLACING BOOMS
E DU C ATI O N

1 . C h o o s e Yo u r B o o m a n d Pe d e s ta l

MXR 32/36 MXR 32/36Z 8

MXR 28/32Z MXR 34/38Z

MXR 24/28Z MXR 36/40Z

Models Horizontal Reach Weight (Boom only)

MXR 24/28Z 78' 1" (23.80m) 8,713 lbs (3,952kg)

MXR 28/32Z 91' 10" (27.99m) 12,591 lbs (5,711kg)

MXR 32/36 105' 2" (32.05m) 13,880 lbs (6,296kg)

MXR 32/36Z 104' (31.70m) 13,239 lbs (6,005kg)

MXR 34/38Z 108' 7" (33.10m) 13,133 lbs (5,957kg)

MXR 36/40Z 115' 2" (35.10m) 13,144 lbs (5,962kg)

Larger boom models including the MXKD 38/42 are also available.

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CUSTOMIZE
E D UC ATIO N
DETACHABLE BOOMS

1 . Ch o o se Yo u r Bo o m a n d Pe d e s ta l

One Boom, Multiple Uses

Detach Booms For total boom versatility and convenience, request our reduce the “fly” weight by 4,850 lbs (2,200kg), and it adapts to
detachable placing booms. This quick attach/detach kit is the most Putzmeister pumps produced from 1985 to present.
perfect choice when transferring the boom on a frequent basis.
The convenient two-piece slewing head features color-coded Series II kits are available to fit your specific needs and can
quick disconnect hydraulic fittings and easy alignment of the be installed with your initial boom pump order or added at
boom to pedestal pin. The pedestal can be left on the tower to a later date.

10
Simple four-step detach process: 9

1. Detach boom and connect crane cables. 2. Lift.

11
12

3. Position and connect pins. 4. Unfold and pump.

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 CUSTOMIZE PEDESTAL DETAILS
E DU C ATI O N

1. Choose Your Boom and Pedestal

13 Putzmeister’s Weight Efficient Pedestal is only

4,850 lbs. (2,200kg)

Lightweight placing boom and pedestal are separate Versatile Pedestal

components so they can be moved together or separately,
depending on crane capacity on-site. Electric version shown.
15

Closeup of pedestal with detail of

filter assembly and lugs above the
connection pins.
14
Just lower the pedestal until the
ears hit the lugs and it perfectly
aligns itself.
16

Manual hydraulic valve controls and

pressure gauge shown.

Electrical panel with convenient

hour meter and hydraulic Note: The electric motor, grease fittings, quick disconnects
cushioning valves on the ends of for hydraulic climbing and compact electrical box make
the swing racks. this package complete.

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CUSTOMIZE
E D UC ATIO N
PIN OR BOLT TOWER – THE CHOICE IS YOURS

2. Specify Pin or Bolt Tower

Pin Tower
17
Tower Design Putzmeister’s Pin System uses four heavy-duty pins instead
Pin and Bolt of bolts for faster and easier connection in installing and
raising the placing boom tower.

Tower sections are connected with four heavy-duty pins:

1. Set one tower section atop another section.
2. Insert four pins.
3. Secure each with a retaining pin.

Simple process done quickly for improved job site efficiency.

• No bolts during tower setup.
• No need for special tools.
• No time-consuming chore of torquing bolts.
• Smooth sides - no protrusions exist.
• Tower easily slides through floor openings without
interruption while being raised. Pin Tower Connection

Bolt Tower 18

Offering years of job-proven reliability and structural integrity,

the Bolt System is a more traditional design.

19

Lightweight adapter is pin-connected for

easy positioning and assembly by hand.
Bolt Tower Connection
20

Closeup of bolt adapter and delivery line with

boom and pedestal removed.

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 CUSTOMIZE
MODULAR SQUARE TOWER
E DU C ATI O N

2. Specify Pin or Bolt Towers

Square and Highly Modular Tower

21 Only Putzmeister offers a square modular tower design: Tower Design

• All Putzmeister MXR placing boom models can Pin and Bolt
connect to the same PM pin or bolt tower.
• Highly modular for greater flexibility and adaptability
to different applications.
• Square design allows for easy reshoring and
simple bracing in building; uses only
hardwood wedges.
• Square tower can be self-jacked or put on base
plates or foundation anchors.
• Square floor openings are easy to block out
and patch.
• Square design allows ladder access and protects
the delivery line and connections all within the tower.
Tower Features:
• Available in varying lengths to accommodate
job sites.
• Can be utilized with all standard Putzmeister MXR
placing boom models – 24/28Z, 28/32Z, 32/36,
32/36Z, 34/38Z and 36/40Z – with horizontal
reaches from 78' 1" to 115' 2".
• Several optional accessories are readily available
for increased job site efficiency.
• Smooth sides without protrusions allow the tower to
slide easily through floor openings.
Accessible Ladder:
• Strategically located inside the tower.
• Positioned on the vertical sides in an
alternating pattern.
• Provides greatly improved access to delivery pipe
and more space when climbing.
Pipe Connect:
• It’s easy to mount pipe to the new tower using
universal connections for the perfect fit every time.
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Pipe Connection

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CUSTOMIZEMOUNTING AND CLIMBING CONFIGURATIONS
E D UC ATIO N

3. Define Your Mounting and Climbing Configuration

Putzmeister Offers the Most Mounting and

Climbing Configurations in the Industry on Both
Pin and Bolt Towers.

23 p. 12 24 p. 13 25 p. 14 26 p. 15

Freestanding Freestanding and Adjustable Wall Bracket Clamp Down

Ballasted Base Mounting Base

27 p. 16–17 28 p. 18 29 p. 19

Inside Climbing Hydraulic Climbing Universal Tie Frame

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 CUSTOMIZE FOUNDATION ANCHORS AND BASE PLATES
E DU C ATI O N

3. Define Your Mounting and Climbing Configuration

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Foundation Anchors and Base Plates

Using four foundation anchors or high strength foundation

Freestanding
base plates, Putzmeister towers can freestand up to 80 ft. Mounting Options
(24m) heights. Contractors realize greater savings when
Pin and Bolt Tower
using Putzmeister foundation anchors and base plates
because they are affordably priced and can be reused for
future projects.

Foundation Base Plate Design:

• Pin tower – each plate easily pins to the bottom of
every leg on the square tower.
• Bolt tower – each plate easily bolts with a two-bolt
connection to the bottom of every leg on the
square tower.
• Ten 1-1/4" (32mm) threaded rods are embedded
into a concrete pad around each plate.
• Uses common off-the-shelf threaded rods, available
Foundation anchors shown with pin tower. from local suppliers anywhere in the country.
33
31
34

Foundation anchors

32

Foundation base plate design for

pin tower.

35

36

Foundation base plate design for bolt

Foundation anchors shown with tower shown with grouting around
bolt tower. the plates.

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CUSTOMIZE FLOOR SUPPORT PLATES AND BALLASTED BASE
E DUC ATIO N

3. Define Your Mounting and Climbing Configuration

Floor Support Plates and Ballasted Base 37

Freestanding and When starting out on an existing concrete slab, four

Ballasted Base floor support plates will enable you to safely mount pin
Mounting Options or bolt tower.
Pin and Bolt Tower
The optional ballasted base is available for freestanding
pin or bolt towers without a foundation.

• Base measures 15 ft. (4.6m).

• Pin tower kit requires additional kit for connection
to base.
• Bolt tower kit connects directly to base.
38

39

Pin tower kit.

40

Pin tower on a ballasted base at the World of

Concrete Mega Demos 2006.
Bolt tower kit. 42

41

Versatile ballasted base can be used as a

Floor support plates shown with bolt tower. clamp down base.

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 CUSTOMIZE ADJUSTABLE WALL BRACKET
E DU C ATI O N

3. Define Your Mounting and Climbing Configuration

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Adjustable Wall Bracket

A Putzmeister exclusive, a wall bracket that does NOT need Adjustable

to be anchored to the forming system – concrete can be Wall Bracket
pumped without any vibration to forms. Mounting Options
Bolt Tower
• Setup and disassembly is quick and easy, as the
wall bracket can be easily lifted by tower crane or
raised with the forming system to be elevated.
• System can be used with any manufacturer’s brand
of self-jacking forms on the market.
• Same bracket can be used with all MXR Putzmeister
America separate placing boom models, no matter
what the boom weighs.
• Adjustable 12" (305mm) range on bottom connection
easily aligns with concrete embeds.
• Wall bracket provides a platform to place a 50 ft.
(15m) freestanding Putzmeister tower anywhere off
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the side of the concrete shear wall.

Bracket Advantages:
• Maintain more precisely aligned forms for a far
superior finished product.
• Control tolerances and reduce wear and tear on
forms for significant cost benefits.
• Easily lift by crane or raise with the forming system
when it is elevated.
• Fits within standard sized elevator shafts for
convenient climbs.

Adjustable 12" (305mm) range on bottom

connection easily aligns with concrete embeds.

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CUSTOMIZE
E D UC ATIO N
CLAMP DOWN MOUNTING BASE

3. Define Your Mounting and Climbing Configuration

Clamp Down Mounting Base

Clamp Down Putzmeister’s clamp down mounting base can be mounted 45

Mounting Base on an existing foundation or structure and can be used with

Mounting Options or without a tower.* Its versatile design enables it to:
Pin and Bolt Tower
• Accomodate tower heights from 10' (3m) to 80' (24m)
• Clamp to the floor truss work.
• Be used with self-climbing form systems where the
base can become part of the framework and ride
with the form scaffolding system for substantial
time savings.

Advantages:
• Small and lightweight.
• Ideal for tight places.
• Flexible – can be used again in different jobs.
• Easy initial assembly.
• Efficient, even for smaller buildings.
• Perfect for barge applications.
*Provided the foundation is strong enough to absorb necessary
reaction loads.

46

47

Pedestal connected directly to clamp down Tower connected to clamp down mounting base.
mounting base.

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 CUSTOMIZE VERTICAL SUPPORT – PIN TOWER
E DU C ATI O N

3. Define Your Mounting and Climbing Configuration

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Vertical Support

Advantages: Inside Climbing

Configurations
The Putzmeister vertical support design supports the Pin Tower
vertical load of the entire placing boom. Once pulled into Inside Static
position, the design is ready to support the tower. All
components are pin-connected for easy assembly and low
component weights.

• Lightweight component is pin-connected to pedestal

for easy positioning and assembly by hand.

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Corner bearing set for pin tower.

Pin Tower Procedure

50

Pin tower corner bearing.

51

52

Lift just past the desired floor level,

then lower a bit.

The tower automatically clicks

into place.

Shown with support feet (purple)

positioned in place, and a corner
wedge set added (green).

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CUSTOMIZE
E D UC ATIO N
VERTICAL SUPPORT – BOLT TOWER

3. Define Your Mounting and Climbing Configuration

Vertical Support 53

Inside Climbing • Vertical support can be attached anywhere on

Configurations the tower.*
• Supports weight of the placing boom and tower
Bolt Tower
Inside Static inside the building.
• Maximum flexibility in slab opening, adjustment of
tower elevation and reshoring design.
• Designed for easy disassembly and reassembly
on each landing.
*Locations are limited on some applications.

With floor frame assembled around tower,

the support arms are pulled back to raise
56 tower through opening. Bolt tower vertical
support shown.
54

Bolt tower corner bearing.

Vertical support frame shown with support

arms locked into lugs on tower, holding boom
Pin and Bolt Corner Bearings: and tower inside the building. Bolt tower
• Lightweight and easy to install. vertical support shown.
• Support horizontal forces on unit.
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• Guide the tower inside slab opening with our
hydraulic climbing system and inside
climbing system.
• Can be used instead of hardwood wedges to
handle horizontal tower forces.
• Sold in sets of four.

Corner bearing set for bolt tower.

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 CUSTOMIZE HYDRAULIC CLIMBING
E DU C ATI O N

3. Define Your Mounting and Climbing Configuration

Hydraulic Climbing
57
Hydraulic climbing is required when a construction Hydraulic
site crane cannot be used or is not available to pull up the Climbing
boom when raising between floors. Configurations
Pin and Bolt Tower
Key Features for Both Towers: Inside Static
• Two hydraulic cylinders – each at 68 pounds (30kg)
– quick disconnect from the hose.
• Hydraulic power is supplied by the pedestal.
• Lightweight components for carrying from floor to floor.
• Hydraulic hose inside tower is protected
from construction.
• Quick disconnect to hydraulic cylinder provided.
• All components are pin-connected for fast
installation and dismantle.
59

Pin Tower - Hydraulic cylinder, hose, lifting

frame and 30 ft. (9m) of climbing ladder.

58

60

Bolt Tower - Hydraulic cylinder, rack set

and hoses.

Pin Tower System

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CUSTOMIZE
E D UC ATIO N
UNIVERSAL TIE FRAME

3. Define Your Mounting and Climbing Configuration

Universal Tie Frame

Universal Tie A universal tie frame* can be used to attach tower with 61

Frame Climbing tie-offs to a building – inside or outside.

Configurations
Pin and Bolt Tower Advantages:
Outside Tie-In • Supported by tower and tied to inside or
outside the structure.
• Used for virtually unlimited tower heights.
• Versatile for applications including:
• Freestanding shear walls.
• Stand-alone cores.
• Individual structures needing high walls and
tower kept away from building.
*Pin tower requires a frame adapter kit.

62

63

Pin Universal Tie Frame Shown

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 CUSTOMIZE RV DECK PLACERS
E DU C ATI O N

Additional System Options – RV Deck Placers

Expand Your Reach Capabilities

Advantages:
• Cost-effective solution for placing concrete when Additional System
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truck-mounted pumps can no longer reach within Options
large surfaces.
RV Deck Placers
• Ideal for complicated floor or bridge work.
• Two-section, manually operated units.
• Maneuvers into tight areas with a 360 degree
articulating boom.
• Up to 4,860 sq. ft. (450m²) areas covered from one
setup location.
RV 7 • Avoids the extra labor and hassle of dragging
delivery lines.
• Lightweight with compact dimensions, easy to
move from spot to spot.
• Quickly transported on and off job sites via truck
65 or trailer.

Model Boom Radius Transport Weight

RV 7 21.6 ft (6.6m) 1,345 lbs (610kg)

RV 10
RV 10 32.7 ft (10.0m) 2,250 lbs (1,020kg)

RV 13 41.3 ft (12.6m) 3,285 lbs (1,490kg)

67
66

RV 13

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PLACING SYSTEM
E D UC ATIO N
CONCRETE PUMPS

The Right Pump Makes the System Successful

Once you’ve made your Placing System choices,

it’s time to select the concrete pump that will
ensure maximum performance.

Concrete Pumps Putzmeister offers the versatility of truck-mounted concrete

boom pumps with the Series II Detach Kit, as well as the
BSA line of trailer pumps. Series II offers the fastest truck to
tower conversion and the BSA 14000 is the most powerful
model available.
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 TRAILER PUMPS FREE FLOW HYDRAULICS
E DU C ATI O N

Putzmeister Free Flow Hydraulics in a

Closed Loop System
69 The pumps at the heart of Putzmeister’s free flow pumping Concrete Pumps
system are bi-directional, variable displacement piston pumps.
Depending on stroke, oil flows in a closed loop from either
port A or port B on the pump to the hydraulic cylinders.

Depending on specific pump cell size, up to 20% of the oil

leaves the simple closed loop system during each stroke
through a flushing valve on the main pump and cycles to a
cooler before it returns to the hydraulic oil tank. Removing
and cooling only this minimal amount of oil is possible
because, unlike an open loop system, the oil flows freely
without passing through any unnecessary valves that can
generate heat.

The closed loop also requires far less oil to run the system,
resulting in a much smaller oil tank.

Speed and timing are also critical to superior performance.

Quicker and more responsive than a hydraulic signal, the
electrical system on a Putzmeister pump minimizes the time
Advantages: it takes to change direction at stroke end.
• Changes in material pressure in the delivery line
are reduced to ensure smooth pumping and a An electrical signal precisely synchronizes the drive
consistent concrete flow. cylinders with the accumulator system that controls the S-
• The intelligent design eliminates wear-inducing Valve in the hopper. Reserved energy stored in a nitrogen
pressure peaks, increases service life and makes bladder is sent as a supercharged blast of oil at precisely
our pumps extremely powerful. the right moment to facilitate a smooth and fast shift of the
S-Valve from one position to another.
• There is greater pump output due to the efficient
use of all available energy.
• Rapid changeover of the stroke means higher
outputs, a smoother flow of concrete and less
boom or line bounce.

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PUTZMEISTER
S I T E
PUTZMEISTER EQUIPMENT SITE REPORTS
R EPO RT S

70

Putzmeister is constantly adding site

reports to our high profile projects

résumé. Please visit the “news”

section at www.putzmeister.com for

a variety of application stories.

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 PLACING BOOM PLACING BOOM SITE REPORT
S I T E R EPO RTS

Extremely Simple and Easy Four-Pin Connection of

Putzmeister Placing Booms Reduces Time and Labor

Putzmeister’s 28-Meter placing boom was the

only logical choice for the development of a
17-story high-rise condo on Key Biscayne.
71
Because of the building location, height and compressed Configuration
schedule, a placing boom was the obvious choice for this Simple Bracing with
project. The highly versatile four-section Putzmeister 28- Vertical Support
Meter placing boom with 92 ft. (28m) reach and PM tower
system were selected for several reasons. An extremely
light flying weight and easy changing between tower sites
was a huge time-saving feature – only possible because of
no counterweight, a convenient four-pin connection, and
an easy delivery line reconnection. Another plus was the
simplicity of horizontal bracing using hardwood wedges and
Putzmeister’s unique lightweight vertical support system
that on this particular job, could be used on any floor,
anywhere on the tower.

When it was demonstrated that substantial savings in time

Two 50 ft. (15m) towers enhance the ability to pour and labor could be achieved by using the Putzmeister
decks as well as columns and walls in a very placing boom with two 50 ft. (15m) tower sites to pour
efficient manner.
decks, walls and columns, Erickson was awarded the job.
72
The first several floors were poured using Putzmeister 43Z-
Meter and 52Z-Meter truck-mounted boom pumps. Then
two towers were dropped into floor openings and used in
conjunction with Putzmeister’s high pressure 12000 trailer
pump for the balance of the structure.

Placing Boom Owner

Erickson Concrete Pumping
Boco Raton, Florida

Authorized Putzmeister America Dealer

Thomas Machinery, Inc.

Did You Know?

Only Putzmeister offers the most mounting configurations
in the industry – freestanding; inside building climbing via
crane or hydraulics; outside building - tied to structure;
along with mounting on a wall bracket; a universal tie frame,
using special support beams or floor support plates; in
addition to a clamp down, ballasted or traveling base.

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SITE REPORT CP 2724-8 US #1 • July 1998 • For more information, call Putzmeister America at (262) 886-3200
PLACING BOOM
S I T E R EPO RT S
PLACING BOOM SITE REPORT

Casting Time Cut Almost in Half with Use of

Time-Saving Putzmeister Placing Boom

Putzmeister’s 28-Meter placing boom becomes 73

vital to making unique “segmental” bridge sections

quickly and cost-effectively for Boston's Big Dig.

Configuration Eliminating the need for ready mix trucks by making their own
Freestanding Precast concrete and using a placing boom for labor-saving continuous
placement, Sanford Precast is projected to cut their casting
time almost in half in comparison to other methods. Using an
electric-powered, skid-mounted Putzmeister Thom-Katt trailer
pump (model TK 50 with variable speed output and low surge
delivery) in conjunction with their placing boom (model MXR
28/32), they are developing 1,600 precast bridge sections
over a 2-1/2 year time frame.

The versatile four-section Putzmeister boom quickly

unfolds inside the building and reaches over working
Freestanding 28-Meter securely
personnel and equipment to place concrete in four, and anchored to building’s foundation.
sometimes, five separate “segment” forms each day. Since
74
each form requires approximately 25 yds. of concrete,
Putzmeister’s TK 50, with maximum 50 cu. yd. (38m3)
output, was teamed with their dependable MXR 28 boom
for peak performance.

The boom is mounted in the center of the building, with the

forms located on a circumference around it. The pump and
batch plant are located about 120 ft. away at the building’s
edge to free up floor space.

The delivery line is placed in a trench across the floor and

routed inside the boom’s tower. This way, the line doesn’t
obstruct movement on the floor and is protected from Only 16 sq. ft. (1.5 m2) of floor space was used for the base
accidental damage near the tower. in this airport hangar, which was converted into a precast
plant.
The 1,600 sections (with the largest ones sized 8 ft. tall x
10 ft. wide x 48 ft. long, and weighing up to 73 tons) will
be hauled one by one via truck on a three hour journey Did You Know?
to Boston for precise piece by piece insertion on the Big
Segmental bridge sections are popular in Europe and
Dig project. the Middle East; however, they are now becoming more
widely accepted in the USA. For the most part, the same
The project, named C-19B1, is anticipated to cost $184 million. holds true for placing booms.

Placing Boom Owner Authorized Putzmeister America Dealer

Sanford Precast - Sanford, Maine D&M Equipment Company
(Division of Modern Continental) Fall River, Massachusetts

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SITE REPORT CP 2724-8 US #2 • August 1998 • For more information, call Putzmeister America at (262) 886-3200
 PLACING BOOM
PLACING BOOM SITE REPORT
S I T E R EPO RTS

Putzmeister Wall Bracket and Detach Boom

Work Together for Efficient Utilization

75
After pouring 2,750 cu. yds. (2,103m³) of concrete
for the foundation of the 28-story Three Bellevue
Center in Seattle, the next challenge was how
to most effectively pour the building’s concrete
core using a detachable boom pump, but without
securing it to the formwork.

This dilemma was solved with Putzmeister’s unique wall Configurations

bracket. Using the bracket, the Putzmeister placing boom Wall Bracket
and tower were attached to the wall of the building’s core
and kept two feet away from the forms. This allowed the
boom, tower and forms to all move up together to the next
level and then be put in place for new sections to be poured.
It also prevented any vibration to the formwork for a more
precisely aligned pour.

The concrete, 400 cu. yds. (306m³) per floor, was pumped
from the ground through a five-inch delivery pipe 315 ft.
(96m) up to the top of the structure. In the end, more than
11,000 cu. yds (8,410 m3 ) of concrete was poured for the
core of this 471,635 sq. ft. (43,816 m2) building.

For the job, Putzmeister’s innovative detach boom kit turned

an existing 28-Meter truck-mounted boom pump into a
separate placing boom.

Because of the ease in removing the placing boom from the

bracketed platform, the detach boom could be easily taken
76
down and used with a 28-Meter truck-mounted pump on
other jobs during a seven-day cycle of pouring, curing and
setting up the formwork for the next floor.
77

M ORE T HAN E QU I PM EN T
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SITE REPORT CP 2724-8 US #3 • July 1999 • For more information, call Putzmeister America at (262) 886-3200
PLACING BOOM
S I T E R EPO RT S
PLACING BOOM SITE REPORT

Putzmeister Wall Bracket Eliminates Vibration

Unmatched Versatility Allows Use with Any Self-Climbing Form System

Putzmeister’s wall bracket addressed the vibration 78

concerns of the formwork supplier assisting with

the tallest building under construction in Omaha
– the $350 million 40-story First National Center.

Configuration Peri Forms voiced concern over a placing boom interfering

Wall Bracket and placing forces on the formwork of the building core. As
there would be 47 different form pours with this high-rise,
each form must align perfectly. The slightest bump off would
cause a mismatch with the very expensive and specially cut
steel and granite pieces destined for the building’s sides in
the finishing process.

Typically, manufacturers tie off to a form and rely on it for

support; however, this results in excessive movement. SS&L
of Omaha, the authorized Putzmeister dealer, informed Peri
Forms that Putzmeister's 50 ft. (15m) freestanding placing
boom configuration mounted on their special wall bracket
79
below the forms system would allow free and independent
movement of the forms. Mere inches away, but not touching
any part of the forms, the tower mounted on the wall bracket
eliminated any vibration and kept the job running smoothly.

Once mounted, the Putzmeister wall bracket eliminated

the need for valuable crane time. Its highly unique design
allowed the Peri formwork itself to lift the boom, tower and
bracket all at once as the center form was raised. By simply
removing the “reusable” concrete embeds and reinserting
them at the next level, the entire lifting process took less
than 30 minutes – a shorter duration and less costly
approach compared to using a crane.

The Putzmeister wall bracket can be used with any Did You Know?
manufacturer’s brand of self-climbing system, allowing it to Wall brackets maintain precisely aligned forms, control
be cost-effectively used on future high-rise projects where tolerances and reduce wear and tear on forms. This
different contractors might be involved. results in cost savings for contractors and achieves a far
superior finished product for customers.
General Contractor
Kiewit Construction
Placing Boom Owner
Omaha, Nebraska Hotz Concrete Pumping
Omaha, Nebraska
Formwork Supplier
Peri Forms
Authorized Putzmeister America Dealer
Canonsburg, Pennsylvania SS&L- Sales, Service and Leasing
Omaha, Nebraska

M O RE THA N EQUIP ME NT
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SITE REPORT CP 2724-8 US #4 • July 1999 • For more information, call Putzmeister America at (262) 886-3200
 PLACING BOOM PLACING BOOM SITE REPORT
S I T E R EPO RTS

Being “Unique” Made a Difference

in 15-Story High-Rise Addition

Did You Know? Due to the highly unique installation of a

After this four-year $345 million expansion project is Putzmeister placing boom and “130 ft. (40m)
finished, the hospital will have doubled its size to 2.4 million tower” through an elevator shaft, the contractor
sq. ft. The approximate total corridor length at this facility saved precious time in completing a 15-story
will then slightly exceed 11 miles.
addition to the largest pediatric hospital in the
80
US – Texas Children’s in Houston.

Although using a 32-Meter separate placing boom and Configuration

tower was the most efficient and logical approach, there Simple Bracing with
was not enough strength in the existing floor to support it. Vertical Support
To combat this, the general contractor used special support
beams on two levels to horizontally brace the tower inside
an elevator shaft. With the vertical load resting on the
elevator’s foundation, the Putzmeister tower was extended
to 130 ft. (40m) – an extremely impressive height for a
placing boom tower.

Adding 80 ft. (24m) onto Putzmeister’s standard 50 ft. (15m)

81
tower while using only two horizontal braces proved to be a
highly specialized installation process. It was only possible
due to the “square” tower’s already versatile and sturdy
design. Plus, this unique installation saved time, as it didn’t
require additional bracing of the high strength tower itself.

Because two towers were needed for this project, the

above approach was implemented using two vacant 8 ft.
x 8 ft. (2.4m x 2.4m) wide elevator shafts purposely built in
1991 for expected expansion. The shafts housed the 130 ft.
Putzmeister tower seen passing (40m) towers to place concrete on the sixth and seventh
through special support beams. floors. Then the adaptable PM towers were pulled to the
82 sixth floor and vertically braced. Climbing inside the building
on every other level until reaching the 20th floor, the towers
stood up to 26 ft. (8m) over the top brace without the need
for counterweight – another exclusive and laborsaving
Putzmeister feature for a placing boom this large.

The pump delivered about 90 yds. an hour (82 m/hr), while

the placing boom stretched to 105 ft. (32m) horizontal
lengths to place approximately 380 cu. yds. (290 m3) of
concrete in the first pour of each floor. The boom was then
quickly flown to the next tower and handled the remaining
Looking down elevator shaft where
130 ft. (40m) of tower passed through
340 cu. yds. (260 m3) of the building.
special support beams down to the
foundation slab. General Contractor
W.S. Bellows Construction Corp. Houston, Texas

M ORE T HAN E QU I PM EN T
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SITE REPORT CP 2724-8 US #5 • October 1999 • For more information, call Putzmeister America at (262) 886-3200
PLACING BOOM
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PLACING BOOM SITE REPORT

Exclusive Putzmeister Equipment Combination

Accelerates Pace of High-Rise Construction

A congested job site benefits from the exclusive 83

features found on a combination of Putzmeister

equipment – BSA 14000 trailer pump, 38-Meter
placing boom and new adjustable wall bracket.
Keeps job on a fast track.

Configurations Although already crowded with skyscrapers, downtown

Adjustable Wall Chicago keeps making room for even more high-rise
Bracket and Corner structures. The latest one under development is Columbus
Wedge Towers. After completing its six-floor parking garage, a
52-story apartment building will follow for a total of 58 levels
ready for use and occupancy in the fall of 2002.

Keeping in line with the fast pace of the Windy City,

this particular contract is calling for an unbelievably fast
completion as well. It requires one apartment floor to be
placed every three days in comparison to the more common
five to six day schedule per floor.

Added to this challenge is the fact that the structure going

up is in a very tight area on Columbus Drive, bordered by
bridges on three sides and another high-rise on the fourth.
84
"Because of the close quarters and height, we had to use a
trailer pump rather than a boom pump, and one with enough
power to get the very dense, high strength concrete up that
high,” said Selton “Sam” Sampson, concrete superintendent
with James McHugh Construction in Chicago, the general
contractor. “This concrete is much harder to push than
normal weight concrete.”

To push the concrete, Sampson is using a Putzmeister BSA

14000 HP-D trailer pump, which is capable of pumping 134
cu. yds. an hour (102m³/hr) at 2176 psi (150 bar).

The unit is pumping concrete to a 38-Meter Putzmeister

placing boom attached to a square placing tower supported
by a Putzmeister adjustable wall bracket. This special
combination of equipment helped keep the project on its
fast track. Did You Know?
Only Putzmeister provides a wall bracket that does
Putzmeister introduced the 38-Meter as its largest placing NOT need to be anchored to the forming system – concrete
can be pumped without any vibration to the forms.
boom on the market that does not require counterweight.

M O RE THA N EQUIP ME NT
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SITE REPORT CP 2724-8 US #6 • Summer 2001 • For more information, call Putzmeister America at (262) 886-3200
 PLACING BOOM PLACING BOOM SITE REPORT
S I T E R EPO RTS

McHugh found its extensive 111 ft. (34m) horizontal reach of the jobs we had coming up, we decided to buy one,”
a necessity for the greatest coverage and its light weight said Sampson.
important for using on-site crane capacity.
He also noted that the trailer pump would be put to good
Plus, moves could be done quickly without the hassle of use in the months ahead because their job plate is full for
counterweight, which saved time: a precious commodity some time to come and the trailer pump should pay for itself
with this job. in a short time.

Putzmeister worked in conjunction with McHugh and Peri Due to the success of this job, the adjustable version is now
Forms, the formwork supplier, to develop a new, adjustable the “standard” style of the Putzmeister bracket. This same
version of their existing wall bracket to accommodate the bracket can be used with all Putzmeister standard MXR
larger sized 38-Meter placing boom. Plus, the adjustable separate placing boom models, no matter what the boom
feature would make lifts easier with a bottom connection weighs, and used with any manufacturer’s brand of self-
that had an adjustable range of 12-in. (305mm) for better jacking forms on the market today.
lining up with the concrete embeds. 85

The newly designed wall bracket proved its worth. It was

attached to the side of an elevator shaft, but not anchored
to the formwork. This meant no vibration to the forms for a
far superior finished product and reduced wear and tear on
the forms for cost savings. Setup and disassembly was also
quick and easy, as the wall bracket was easily raised with
the forming system when it was elevated. It could have also
been raised by crane if preferred.

Will pour a total of 38,000 yds.

Sampson said, “Including the parking area, we’ll eventually
pour more than 38,000 cu. yds. (29,053m³) before
we're finished.” Peter Spear, McHugh’s Equipment
Superintendent stands next to the
wall bracket.
Fortunately, the smooth operation of the Putzmeister placing
boom and the long strokes of the most powerful trailer pump 86
on the market today help to make the concrete placement
both safe and efficient.

“I can't say enough about that trailer pump,” said Sampson.

“It's perfect for a job in downtown Chicago where you don't
have a lot of space and yet have to go up pretty high.”

He had used a Putzmeister trailer pump to pour the floors

of the 74-story Park Hyatt. Located on Michigan Avenue in
Chicago’s historic Water Tower Square, this hotel opened 58-story high rise relies on 38Z-Meter
in June 2000. “After seeing what it could do, and because and BSA 14000 trailer pump to quickly
handle concrete job.

M ORE T HAN E QU I PM EN T
30 SITE REPORT CP 2724-8 US #6 • Summer 2001 • For more information, call Putzmeister America at (262) 886-3200
PLACING BOOM
S I T E R EPO RT S
PLACING BOOM SITE REPORT

Clamping Down for Increased Productivity

Efficiency of Putzmeister Clamp Down Base Changes
Thinking on How All High-Rises Should Be Built

Lancaster, a 30-story residential complex, is the 87

first of several planned high-rise structures being

built in the new Lakeshore East development within
the downtown Chicago Loop. Under an extremely
fast-paced time frame, the building is also the first
to be constructed using a more efficient way to
place concrete by the general contractor.

Configurations Instead of climbing a placing boom tower in a previous

Clamp Down manner, the general contractor is the first to use a specially
Mounting Base designed Putzmeister clamp down mounting base for increased
productivity in constructing the 324 ft. (99m) tall building.

The general contractor is James McHugh Construction, 88

a family-owned business established in 1897. The $250

million McHugh company is known as a concrete innovator,
and thereby receptive to new construction techniques.

Putzmeister’s development of the special clamp down

mounting base accommodated McHugh’s request for a
different way to construct the Lancaster project. Ironically,
the huge success of the base is making the contractor
take another look at how all high-rise structures should
be constructed in the future. This includes smaller 18-
story buildings that may have considered a placing boom
impractical in the past.
89
According to Ken Hoyle, the project’s superintendent,
“Because of the clamp down base, we can do an
‘easy’ three day schedule. With this mounting design, we
eliminated an entire step in raising the base, and that
helps save a day overall.”

Hoyle added, “With an ‘easy’ three day approach, even if it

rains for half a day or another problem occurs, we still have
enough time to absorb any minor delays without affecting
the cycle.”

Used with a self-climbing form system, the base conveniently

becomes a part of the framework and rides with the system, Did You Know?
as it's hydraulically raised within the core. Since the base is Putzmeister’s clamp down base is unique because it can
not independently connected to any tower, but instead moves work with or without a tower, plus be used over again in
with the forms, substantial time savings are realized. other jobs.

M O RE THA N EQUIP ME NT
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SITE REPORT CP 2724-8 US #8 • May 2004 • For more information, call Putzmeister America at (262) 886-3200
 PLACING BOOM PLACING BOOM SITE REPORT
S I T E R EPO RTS

The initial assembly was also less involved, as the base core system with the boom, pedestal and base attached.
was merely clamped down to structural beams, which We then reconnect the riser line, and we're ready to pump
were reinforced to a load factor of 48,000 lbs. (22,000kg). again. It’s that simple. Since we don’t have to break from a
This was necessary to absorb the reaction loads needed tower, we're saving about three guys doing four to five hours
to accommodate the 18,000 lb. (8,200kg) MXR 34/38 of extra work.”
placing boom and its pedestal when at a full 111 ft. (34m)
horizontal reach. McHugh predominantly purchases their own construction
equipment for added control in scheduling their jobs.
Using a placing boom with a longer reach also provides According to Pete Spear, Equipment Superintendent for
a greater area of coverage when placing concrete. This McHugh, “All the placing equipment is working exceptionally
means the boom can remain in the same location without well, especially the clamp down method. It saves a
crane moves or adding extra delivery line. In addition, tremendous amount of labor because it’s really fast. We
Putzmeister placing booms do not require counterweight, discovered a few helpful tricks along the way so now there’s
so this also makes the process run even smoother. no fooling around when it’s time to elevate the system to
the next floor.”
Meanwhile, the back end of a Putzmeister 32-Meter
concrete boom pump is used like a trailer pump to push the Spear also noted that, “The clamp down base is small,
concrete up. lightweight and has a flexible design so we can and do plan to
use it over again in other high-rise projects being planned.”
Hoyle said, “Because of the effective setup, we’re getting
about 115 yards an hour (105m/hr), which is 40 yards (36m) Although this job’s setup used the clamp down base at zero
more than expected. Of course, the faster you place the elevation without a tower, it can also be used with a tower.
concrete, the faster you can get to the next step.” Therefore, McHugh has the flexibility of attaching it to an 80
ft. (24m) freestanding tower for climbing or to a 20 ft. (6m)
The aggressive three-day construction cycle for each floor tower within the form frame system to accommodate future
now begins with the placing boom placing concrete for the requirements.
deck for three hours in the morning of the first day. A special
accelerator in the concrete allows the 13,700 sq. ft. (1,272 m2) Overall, the convenient process has McHugh rethinking
area to harden in about three hours. other projects that could benefit from the overall time
efficiency of using a placing boom with the base versus
As the concrete cures, the crew cleans up, reprimes and other alternatives.
then starts pouring the vertical interior and outside columns
in the afternoon. A total of 430 yds. (393m) of concrete is The Lancaster project will consume over 18,500 yds.
placed per level. In addition, 60 percent of the floor frame (16,916m) of concrete, which includes an adjoining post-
for the next upper level is accomplished the same day. tensioned four-story garage with a multi-strand constructed
For the most part, the carpenters, laborers, finishers and bridge over the top of it, along with the 30-story high-rise
ironworkers must then complete their portion of the job building itself. Plans are to complete the entire Lakeshore
within the following two days. East development by 2010.

“The ‘two-day work, one-day pour’ process is ready to General Contractor

repeat itself once a floor is finished and the placing boom James McHugh Construction
and pedestal are raised,” said Hoyle. “To get to the next Chicago, Illinois
level, we basically disconnect the riser line and jack up the

M ORE T HAN E QU I PM EN T
32 SITE REPORT CP 2724-8 US #8 • May 2004 • For more information, call Putzmeister America at (262) 886-3200
PLACING BOOM
S I T E R EPO RTS
PLACING BOOM SITE REPORT

Big Bridge, Big Equipment

Putzmeister Technology Helps Build Concrete Bridge with Greater Efficiency

At a point where the blue waters of the Puget 90

Sound become a narrow channel almost a mile

wide, the Tacoma Narrows Bridge, one of the
largest suspension bridges to be built in the US
in 40 years, connects a gap from the Washington
mainland to the Olympic Peninsula.

Configurations The location south of Seattle, Washington, presents

Clamp Down significant challenges, as the Tacoma Narrows is located in
Mounting Base a seismically active area complicated by high winds, 15 ft.
Freestanding (4m) tidal swings, and seven-knot currents.
Artist’s Rendering
The first cable-suspended bridge was built there prior to
WWII. However, it was a failure, nicknamed “Galloping 91

Gertie” for the way it swayed in the wind. The bridge

collapsed about four months after it opened in 1940.

As a result, its replacement was a more aerodynamically

sound steel bridge, and today it is the fifth largest suspension
bridge in the United States. However, since the bridge’s
opening in 1950, traffic volume has soared to over 90,000
vehicles a day – 30,000 more than the maximum for which it
was intended. Therefore, it became paramount to construct
another bridge to reduce traffic congestion.

The new 2007 Tacoma Narrows Bridge will be 5,400 ft. 92

(1,645m) in total length, 2,800 ft. (853m) in the main span.
Being constructed directly parallel to the current Narrows
Bridge, it will provide three eastbound traffic lanes, shoulders on
both sides, and a separate bicycle/pedestrian path. Meanwhile,
the current bridge will be reconfigured to carry three westbound
traffic lanes.

Although the center lanes of the two bridges will only be

200 ft. (60m) apart, the two structures won’t look alike. The
existing bridge towers are green and made of steel.

The new bridge towers will be a coated gray with pigmented C o n c r e te t r ave l s v i a a f i ve - i n c h d e li ve r y
li n e located along the current bridge.
sealer and built of reinforced concrete. That’s because
today’s technology makes concrete much more practical
than steel as a more cost-effective medium and with
significantly lower maintenance.

M O RE THA N EQUIP ME NT
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SITE REPORT CP 2724-8 US #9 • April 2007 • For more information, call Putzmeister America at (262) 886-3200
 PLACING BOOM PLACING BOOM SITE REPORT
S I T E R EPO RTS

After concluding the design, the first major task was to concrete trailer pumps were the only units to offer both the
construct two of the largest caissons ever built, forming the high volume and high pressure combination needed for
foundation for the 510 ft. (155m) tall piers. pumping concrete on the job. The units have electric twin
motor drives and were capable of outputs up to 130 cubic
Each caisson – equivalent to a 20-story underwater building yards an hour (99m3/hr). Their maximum pressure is 3,190-
– contains 38,000 cu. yds. (29,053m3) of concrete and can psi (220 bar).
accommodate the weight of a second deck (either road or
light rail) in the future. Finally, no counterweight on the placing booms was required,
even with the larger sized models selected for extended
Proposals of how to efficiently concrete the caissons were reach. The lack of counterweight was a significant factor to
presented to the firm of Tacoma Narrows Constructors, a keep the center of gravity as low as possible on the barge.
joint venture of Bechtel and Kiewit Pacific.
Therefore, with a 125 ft. (38m) horizontal reach, the
Product specialists Bill Carbeau of Putzmeister America and Putzmeister MXKD 38/42 placing booms were selected.
Rolf Dose of Putzmeister-AG in Germany masterminded a They were deemed both long enough for efficient
strategic plan for the project. concrete placement and high enough to clear the rebar
above the pour.
First, the technical plan allowed for pumping concrete from
93
land versus hauling concrete on a barge. Therefore, ready
mix trucks could conveniently discharge directly into a
concrete pump's hopper from shore.

Concrete would travel via a five-inch delivery line along the

current bridge until it was necessary to cross down 165 ft.
(50m) and over to a pumping barge.

At that point, a ramp would hold the delivery system,

which had two five-inch steel braided Putzmeister hoses to
accommodate the tide.
A ramp holds the deliver y system,
Second, the use of Putzmeister’s advanced ZX pipeline w h i c h features two five-inch steel
alleviated environmental concerns about concrete spillage braided hoses.
in the water. ZX delivery line and couplings are leakproof 94
and rated for extremely high pressures.

Bill Carbeau, Telebelt® and Specialty Products Sector

Manager for Putzmeister America, said, “The ZX pipeline
and couplings were originally designed by Putzmeister for
use in sewage treatment plants where it’s critical to prevent
leaks. However, the technology was successfully applied in
this application, and it proved to be absolutely leak free and
trouble free.”

A third factor in selecting the plan was the pumping

A Putzmeister DVH 5/2 diversion valve
equipment’s design. The proposed Putzmeister BSA 14000 assists in the process.

M ORE T HAN E QU I PM EN T
34 SITE REPORT CP 2724-8 US #9 • April 2007 • For more information, call Putzmeister America at (262) 886-3200
PLACING BOOM
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PLACING BOOM SITE REPORT

Caisson Construction
Once the Putzmeister strategy was selected, developing noted, “Two freestanding 40 ft. (12m) towers were bolted to
the two needed caissons was a “go.” At the nearby Port of a single floating barge, where it was necessary to flood the
Tacoma site, 62 ft. (19m) high steel forms were built atop chambers to achieve a zero-degree elevation with no more
a cutting edge, which is the base of a caisson. The bottom than a plus or minus three-degree list. This was to offset the
edges of this structure are tapered so they cut through the loads imposed by the two booms, which were mounted next
seabed as a caisson is lowered into place. to each other on the same side of the barge.”

Ultimately the BSA 14000 pumped concrete into its walls, From land, concrete was pumped by two BSA 14000 concrete
whereby a caisson started. Because of the weight, the structure trailer pumps, each using 1,500 ft. (457m) of ZX delivery line
dropped 30 ft. (9m) beneath the water’s surface as planned. to reach one caisson. Meanwhile, the placing booms placed an
Both caissons were initially prepared in this manner. average of 1,200 cu. yds. (917m3) of concrete in a day pour.

In July of 2004, three tugboats towed the first caisson to the Then the barge moved to the caisson on the other side
construction site 11 miles (18km) away. The theory was for of the Puget Sound to pump the following week. To pump
the ingoing tide to bring the caisson in from the port and the the other caisson, two BSA trailer pumps were now set up
outgoing tide to handle the final maneuvering. on the other side of the bridge using 2,200 ft. (670m) of
delivery line.
Nothing is simple, however, when the present 15,240 ton
structure is being towed. At this point in its development Overall, this flip-flopping approach meant the 210 ft. (64m)
stage, the caisson was essentially a seven-story high box, tall caissons could be built in a concurrent manner. When
130 ft. long, 80 ft. wide, 80 ft. tall (40m x 24m x 24m) – and completed, the cutting edge was sealed with concrete, and
partly submerged. eventually went through about 150 ft. (46m) of water and 60
ft. (18m) of seabed to reach solid footing.
The days following, the structure was precisely maneuvered
into position. With only a small margin of error allowed, divers The crew never encountered even one minor problem with
used GPS to locate and thus help secure the caisson with the high pressure trailer pumps or separate placing booms
cables to prepositioned anchors embedded in the Tacoma on the highly technical job.
Narrows floor. Later in August, the second caisson traveled to
95
its final destination and was handled in the same manner.

Over the next few months, the two structures - mostly hollow
and each floating on 15 steel air domes - gradually sunk as
a series of 10 ft. (3m) reinforced concrete walls were added
atop each caisson.

Two MXKD 38/42 placing booms were responsible for

simultaneously placing the concrete; and each had the ability
to cover the other’s area as a backup measure - although
this proved unnecessary as no technical problems were
encountered. The average output was 60 cu. yds. (54m3) an
hour with line pressures as high as 2,000 psi (138 bar). With 125 ft. (38m) reaches, the placing booms proved to
be long enough for concrete placement and high enough
The bigger placing booms required larger versions of the to clear the rebar above the caisson pours.
company’s standard modular design towers. Bill Carbeau
M O RE THA N EQUIP ME NT
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SITE REPORT CP 2724-8 US #9 • November 2004 • For more information, call Putzmeister America at (262) 886-3200
 PLACING BOOM PLACING BOOM SITE REPORT
S I T E R EPO RTS

Pier Construction
Pier construction started in September 2004. Because of The new Tacoma Narrows Bridge is expected to open in
the success in pumping the caissons, Putzmeister 2007. Upgrades to the existing Tacoma Narrows Bridge
equipment was also utilized for pumping the piers. will be completed in 2008. Overall, the project cost is
presently estimated at $849 million.
Therefore, before being disassembled, the existing placing
boom setup was used to place concrete as high as the units When finished, the overall project will have consumed over
could reach - another 70 ft. (21m) above the caissons. 255,000 cu. yds. (194,961m3) of concrete.

96
The same Putzmeister BSA 14000 trailer pumps were set
up underneath both ends of the new bridge, again using a
total of 3,700 ft. (1127m) of ZX pipe to deliver the concrete,
but this time to a bucket.

The bucket, in turn, placed the concrete in the tower’s forms,

which could only withstand a maximum of 24 cu. yds. an
hour (18m3/hr).

When reaching the struts, a BSA 14000 trailer pump will pump
the concrete all the way to the top of the strut’s 140 ft. (42m)
height, while a tower crane assists by holding the pipeline.

A system of concrete forms called “bird cages” is being used to

build each leg of the hollow towers in 17.5 ft. (5m) increments.
With each caisson and pier nearly as tall as Seattle’s Space
Needle, they will consume a total of 16,000 cu. yds. (12,232m3)
of concrete when completed in April 2005.

Of special note is the concrete mix for the piers. It is both

strong and dense to keep salt spray and acid rain from
penetrating the piers’ steel skeleton, and it incorporates
plasticizers and fly ash. Typically, bridge tower specs call for
a 7,000 psi (483 bar); however, this mix is closer to 11,000 General Contractor
Tacoma Narrows Constructors - a joint venture of Bechtel
psi (758 bar).
and Kiewit Pacific

Cable Anchors Concrete Placing Equipment

Telebelt® conveyors are placing concrete to anchor the cables • Putzmeister MXKD 38/42 separate placing booms
(2) and ZX delivery line
for suspension. “Truck-mounted Putzmeister belt conveyors • Freestanding 40 ft. PM towers (2)
are an ideal solution because they can place the larger size • BSA 14000 trailer-mounted pumps (3)
aggregate fast and without the possibility of plug-ups,” noted • TB 105 and TB 130 Telebelt® conveyors
Carbeau. “When finished, the two cables will each consume • Putzmeister boom pumps - all sizes
26,000 cu. yds. (19,878m3) of concrete.” • Putzmeister hydraulic diversion valves
• Putzmeister clamp down mounting base

M ORE T HAN E QU I PM EN T
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SITE REPORT CP 2724-8 US #9 • November 2004 • For more information, call Putzmeister America at (262) 886-3200
PUTZMEISTER
S I T E R EPO RT S
PUTZMEISTER EQUIPMENT SITE REPORT

Power Plant Construction Needs Powerful Equipment

Putzmeister Equipment Meets Concrete Placement Demands
of Eastmain-1 Dam and Powerhouse Project

A wide variety of Putzmeister equipment assists

in several construction aspects of the massive
Eastmain-1 project for Hydro-Québec.
Configuration The ongoing energy development of Hydro-Québec is 97

Ballasted Base part of a $2 billion project undertaken by SEBJ – Societe

Energie de Baie James. For Hydro-Québec, SEBJ has
been instrumental in the development of a very rich
hydroelectric area via numerous power stations installed
since the 1970s.

In particular, construction of the new Eastmain-1 hydroelectric

power plant – located on the Eastmain River near James Bay
– is designed to generate 480 megawatt of electric power for
Hydro-Québec.

The project – underway in a desolate region in northern

Québec – includes a powerhouse, a main dam across the
Eastmain River, the spillway on the river’s right bank, and 33
dikes for reservoir closure. Construction was broken down
98
into five major contracts, awarded independently via open
public bids.

The largest of all structures being built is the 150 ft. (50m)
tall, 410 ft. (125m) long and 180 ft. (55m) wide powerhouse
– where three huge turbines will generate the power. This
surface powerhouse, built into a rocky hill, is on the left bank
of the Eastmain River. By the time the water exits through
the tailrace, it will have dropped over 200 ft. (60m) from the
water intake. This head, combined with the flow, develops
kinetic energy that causes the turbines and generators to
turn, producing electricity.

In particular, the major $108 million Canadian powerhouse,

penstocks, and water intake project were started in the
spring of 2004 under the direction of Canadian contractor Did You Know?
Aecon Hochtief. The Aecon Group is Canada’s largest
The web site - w w w.hydroquebec.com - of fers
publicly traded construction company, and the group is detailed information along with photographs and
49 percent owned by German construction giant Hochtief animated illustrations, which help guide you through the
(parent of US-based Turner). entire and unusual construction process of Eastmain-1.

To help place concrete more efficiently, Pompaction, Inc.

of Pointe-Claire, Canada is supplying the concrete placing
equipment for the major feat.

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 PUTZMEISTER PUTZMEISTER EQUIPMENT SITE REPORT
S I T E R EPO RTS

In particular, the contractor needs reliable equipment, as They would also help keep wear costs to a minimum with
Montreal is the closest inhabited area at over 750 miles their inherently long 83-inch (2,100mm) stroke cylinders and
(1200km) away. Therefore, if a machine fails in the job’s up to 2205-psi (152 bar) high pressure capabilities.
isolated location, it costs an exorbitant amount in down time.
Without a set pattern, pumping occurs on an irregular basis.
Project Manager Ken Chryssolor of Aecon Hochtief said, Average outputs range between 25 to 80 cu. yds. an
“For over 30 years, I’ve worked on huge jobs within James hour (20 to 60m³/hr) – with the rate of placement governed
Bay so I know how difficult the abrasive granite mix is to by the specifications and the complexity of the intricate
pump. As we needed high performance equipment that forms, not by the equipment capabilities.
could handle the tough aggregate mix, we’re depending on
all Putzmeister products.” Of the two trailer pumps, one serves as the main production
unit being fed via a Putzmeister JT-5000 jumbo trough – a
For the specific powerhouse and water intake project, surge hopper directly flanged to the pump’s hopper. The
the mix of equipment includes two BSA 2109 H-D high jumbo trough allows a quick and full discharge of the mixer
pressure trailer-mounted concrete pumps, a JT 5000 jumbo trucks into its large capacity hopper, which in turn allows
trough mixer, and two PM towers for mounting specially concrete to be fed to the pump at any speed needed from 0
modified MXR 30Z-150 separate placing booms. The two to 125 cu. yds. an hour (0 to 95m³/hr).
Putzmeister placing booms were originally standard MXR
34/38Z units modified by shortening the boom length to 30 99

meters to make up for the weight difference in using the

six-inch pipe required.

Instead of typical five-inch pipe, six-inch was needed

throughout the delivery system in handling the extremely
harsh concrete mix supplied by the on-site batch plant. The
brutal mix comprises crushed granite at one and one-half
inches wide yet an inconceivable four inches long.

Due to the abrasive mix, high pressures, and up to 500 ft.

(150m) pumping distances involved, Putzmeister ZX pipes
and couplings are also being used.

Ken noted, “We needed heavy-duty pipe and couplings for 100

handling the extremely hard aggregate mix and for long

usage life. Putzmeister’s special ZX pipe and couplings
are completely leakproof and high pressure resistant. They
definitely outlast any standard pipe and are an absolute
necessity for this application.”

Two Putzmeister BSA 2109 H-D trailer-mounted concrete

pumps were also selected because of their field proven S-
Valve for handling the coarse mix.

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PUTZMEISTER
S I T E R EPO RT S
PUTZMEISTER EQUIPMENT SITE REPORT

The second Putzmeister trailer pump serves as backup 101

because cold joints are absolutely forbidden or the

powerhouse would be structurally deficient. Consequently,
in case of an equipment malfunction, the second pump can
finish a pour.

Ken said, “We basically have to almost duplicate equipment

needs because of our remote location 15 hours away from
Montreal. With 600 men on a job, we can’t afford down
time. Fortunately, no major problems have resulted to
date, and the equipment has performed to our demanding
expectations.”

From April to November 2004, concrete work for the

powerhouse took place. Two 75 ft. (24m) tall placing boom
towers were anchored with bolts and had to be precisely 102

mounted in specified locations so no cold joints would

interfere with the flow of water upon project completion.

The two placing booms – each using their full 100 ft. (30m)
horizontal reach – first provided full coverage to place
concrete for both the walls of the huge turbines and the
powerhouse structure itself.

In November, the two towers were moved to handle the

intake structure. This time, they were supported by 15 ft.
by 15 ft. by 4 ft. high (4.5m x 4.5m x 1.2m high) poured
concrete mats, and the placing booms still provided ample
reach to all concrete placing areas.

Especially noteworthy is the placing boom’s Multi-Z boom 103

configuration, which proved exceptionally maneuverable in

working under the low roof of a temporary overhead steel
structure. The structure was specially built so construction
could continue during the frigid winter months.

Aecon Hochtief is also handling the horizontal concrete

work for the penstocks. The three enormous penstocks are
concrete-lined conduits excavated in the rock to channel
water from the reservoir to the powerhouse turbines and
are designed to maximize the head (drop in level). A
Putzmeister BSA 2109 H-D trailer pump is pumping the
concrete lining of these 350 ft. (107m) long penstocks, each
at a 25 ft. (7.6m) diameter ranging from a 12-inch (305mm)
to 4 ft. (1.2m) thickness.

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SITE REPORT CP 2724-8 US #10 • September 2005 • For more information, call Putzmeister America at (262) 886-3200
 PUTZMEISTER PUTZMEISTER EQUIPMENT SITE REPORT
S I T E R EPO RTS

Besides the equipment’s proven performance, service Even the PWT high pressure washers – the latest
and support capabilities were a significant factor in addition to the Putzmeister America product line – were
Aecon Hochtief selecting Pompaction for their equipment on-site working six months for Neilson Construction of
needs. Pompaction assisted in specifying the appropriate Québec City. Next to the dam, two 500th models sprayed
equipment, helped train operators, and is making service water at high 7,500 psi (520 bar) pressures to thoroughly
calls when deemed necessary. clean selective areas of rock before concrete placement
was possible.
And making service calls isn’t easy. As a closed site, entry
is by invitation only via SEBJ (Air Creebec) aircraft or a 15 In summary, Francis Gagnier, Vice President at Pompaction
hour drive from Montreal. That’s why a specially developed said, “We’ve sold several different pieces of Putzmeister
work camp was built to house construction site workers, equipment to various contractors working on this enormous
who in staggering shifts work 42 days followed by a ten and demanding project complex. That alone is valid testimony
day leave. to the value placed on the equipment’s performance and
reliability within such a remote location.” Plans are for the
During a peak period last summer, nearly 2,400 workers facility to be operational by late 2006.
were housed in dormitories. Similar to a small town, the
site offers a variety of services such as cafeteria, hair CONTRACTOR SPECS
salon, convenience store, post office and library along with Concrete placing equipment dealer
indoor and outdoor recreational facilities. Once the project is Pompaction, Inc.
complete, the approximate one-half square mile work camp Pointe-Claire (Montreal), Canada
will be dismantled and transported to another job site. General contractor for powerhouse and
water intake structure
Besides building the concrete intensive powerhouse, other Aecon Hochtief
construction projects on site are also utilizing various General contractor for penstocks
Putzmeister models, resulting in a monopoly of Putzmeister Norascon-Hebert – Québec, Canada
equipment on Eastmain-1. This includes a BSA 1409 General contractor for Eastmain dam
electric-powered trailer pump being used by Norascon- EBC Inc.- Québec City, Canada
Hebert, a joint venture between two established businesses General contractor for spillway
in Quebec. The unit is competently placing concrete for all Hamel Construction – Québec City, Canada
incline work associated with the penstocks. General contractor for dikes - reservoir closure
Neilson Construction
In addition, a Telebelt® TB 105 belt conveyor was utilized for EBC Inc.
placing concrete on the main dam across the Eastmain River. CCDC (EDM Construction)
The contractor, Hamel Construction of Québec City took full Fernand Gilbert Excavation
advantage of the conveyor’s special functionality to place
unusually tough mixes and other aggregates such as sand, PUTZMEISTER EQUIPMENT
gravel and rock with ease. • BSA 2109 H-D trailer pumps (2)
• JT 5000 jumbo trough mixer
• PM towers (2)
For construction of the numerous dams, various Thom-Katt® • MXR 30Z-150 separate placing booms (2)
trailer-mounted pump models were utilized for shotcreting by • Putzmeister ZX pipe and couplings
Norascon-Hebert and also by EDM Construction of Québec • BSA 1409 E trailer pump
City, who were subcontracted by CCDC in Montreal. In • Telebelt® TB 105 belt conveyor
addition, a Putzmeister SP-11 diesel-powered rotor/stator • SP-11 rotor/stator pump
• Thom-Katt® trailer-mounted pumps
pump handled injection grouting for EBC, Inc. of Québec City. • PWT 500th high pressure washers (2)
• Putzmeister ballasted base

M ORE T HAN E QU I PM EN T
40 SITE REPORT CP 2724-8 US #10 • September 2005 • For more information, call Putzmeister America at (262) 886-3200