Burj Dubaj - urządzenia do pompowania betonu.pdf - Referaty - SZEF_m

Steffen Kimmerle

Budowa budynku Burj w Dubaju –

omówienie urządzeń do pompowania betonu

ConstruCtion works at the Burj DuBai tower ConstruCtion

site - maChinery anD ConCrete pumping operation

Streszczenie

Referat omówi sprzęt zastosowany do pompowania betonu na placu budowy najwyż-

szego na świecie budynku w Burj Dubai, jego usytuowanie oraz rozwiązania techniczne

umożliwiające pompowanie betonu na wysokość ponad 600 m.

Abstract

The paper presents the industrial machine for pumping concrete at the construction site of

the highest building in the world - the Burj Dubai Tower in the United Arab Emirates. It

was discussed the set-up of the machine and the over 600 m high-rise concrete pumping

technology.

Steffen Kimmerle – Putzmeister Concrete Pumps GmbH

Steffen Kimmerle

After repeated extension of the use of the last remaining Putzmeister Super High

Pressure trailer concrete pump 14000 SHP D over the past months at Burj Dubai, on 9

April 2008 the concrete delivery was completed reaching a new world record height of

606 m. The pump height is calculated from the length of the riser secured in the structure

and the vertical delivery line including the tubular column and stationary boom.

As a result of the predominantly steel construction of the last tower levels and the low

concrete quantities used above 586m, the concrete pump was barely working to capacity

for more than a few hours per week. Due to the disassembly started in the meantime, the

building’s guided delivery line is no longer interfering Burj Dubai’s interior fittings.

During the last pump operations, a concrete pressure of 200 bar was measured on

the Putzmeister trailer concrete pump with S transfer tube 14000 SHP D with an output

of 28 m 3 /h. Overall, the three Putzmeister high-performance pumps have, during their

32 months of operation, pumped approximately 165,000 m 3 of high-strength concrete.

This exclusively involves concretes of the property classes C50 for the floors as well as

C60 and C80 for the walls of the central core. With a 606 m height difference, the concrete

required approximately 40 minutes from the filling into the hopper to its discharge from

the delivery line. The concrete volume in the line (nominal diameter 150mm up to 550 m

height, after this ND 125) amounted to approximately 11 m 3 with this installation height.

This equates to a weight of over 26 tonnes on the Putzmeister concrete pump after every

piston stroke when the S transfer tube is switched.

Not only the pump operator Unimix, but also Putzmeister Concrete Pumps GmbH as

the manufacturer of the high performance concrete pumps, have seen confirmation of the

results gathered during the extensive trials before starting the extreme high-rise pumping.

Through intensive support of the machines and logging of extensive data and system infor-

mation during the concrete placement, PM engineers gained extensive experience for future

high-rise projects. Incidentally, the consortium’s briefly discussed suggestion of installing a

relay pump at a height of around 400 m “by way of precaution” to support high-rise concrete

pumping if necessary, was not implemented. Instead, all those involved assumed that the

final pumping height would easily be reached with this BSA 14000 SHP D.

This extreme pump height was possible due to the trusting cooperation between the

Samsung-led team, the machine operator Unimix, the local Putzmeister agent German

Gulf Enterprises, as well as the Putzmeister parent company in Germany.

The Putzmeister high-performance pump on the ground

also provides for a consistent concrete stream at a

height of over 600m.

DNI BETONU 2008

Construction works at the burj dubai tower construction site ...

The Burj Dubai in April 2008 –

the 159th structural level already

concreted in the meantime.

The client, Emaar Properties (UAE), has commissioned a consortium managed by

Samsung (Korea) together with BeSix (Belgium) and Arabtec (UAE) with carrying out

the construction works on what will be the highest building in the world, at over 800 m.

Turner Construction (USA) is responsible for the project management.

With three Putzmeister high performance concrete pumps, a sophisticated delivery

line system, four stationary booms and challenging concrete mixtures, the carcass of the

Burj Dubai has been under construction since the start of 2005. Due to the rapid progress

in construction and the narrowing building structure as it rises upwards, three of the

stationary booms have in the meantime been dismantled and one of the stationary pumps

removed.

A proper amount of trust in the know-how and reliability of the partner was requ-

ired when Unimix - responsible for concrete production and delivery at the Burj Dubai

- decided to commission Putzmeister AG with the supply and installation of the pumps

and boom systems. Through earlier pump tests, Putzmeister had already determined

that the concrete pumps and pipelines for delivery heights of up to 600 m were suitable

at an output of around 30 m 3 /h. It was also known that the tip of the Burj Dubai would

be erected in a lighter steel construction from level 156, for static reasons, and that only

the decks would be concreted up to level 160 (611 m height).

High-rise pumping simulated in extensive preliminary tests

PM’s preparations at the start of 2005 were correspondingly thorough as well as extreme-

ly time-consuming and human-resource intensive, both at the Aichtal Works and at the

construction site in Dubai. On site, extensive tests were carried out with horizontally laid

pipelines in a large series of tests and with the support of the local PM agent German Gulf

Enterprises (GGE – see info box on page 11). The reason was to simulate the pressure be-

haviour and the expected friction of the concrete in the pipeline based on the later mixture

breakdown and to convert it to the high-rise pumping. The tests were carried out using a

series produced BSA 14000 HP-D high-rise pump and ZX delivery line (DN 125).

DNI BETONU 2008

Steffen Kimmerle

To simulate high-rise concrete

delivery under extreme condi-

tions, hundreds of metres of

delivery line were laid horizontally

in a test phase, measurement va-

lues and factors such as friction

coefficients were determined and

converted to high-rise pumping.

Super high pressure pumps adapted to the extreme conditions

In the Putzmeister Aichtal Works, the details of the new super high pressure pump to

be developed were already fixed at this time. It had to be constructed and delivered by

summer 2005 for the imminent high-rise pumping. With the BSA 14000 SHP-D – the cor-

rect name for extreme pumps – components including the frame and hopper have been

reinforced to be able to withstand the enormous forces. Putzmeister had also adjusted

the S transfer tube and S transfer tube bearings in respect of the expected pressures. To

avoid contamination of the hydraulic fluid with water or dirt particles from the outset,

the BSA 14000 SHP-D also has a particularly effective filter system. Above all, however,

Putzmeister engineers have modified the drive hydraulics so that the translation ratio

One of the BSA super high-pressure pumps during

night-time use

DNI BETONU 2008

Construction works at the burj dubai tower construction site ...

between the hydraulic and the concrete pressure is less than i=1 with piston side ope-

ration. Due to this hydraulic ratio, concrete pressures of over 400 bar (max./theor.) are

possible with the high-performance pumps. As the Putzmeister engineers were expecting

significantly lower pressures during the later job, however, the pressure of the concrete

pumps was limited and delivery lines were installed with “just” a maximum of 250 bar

operating pressure.

Unimix has combined two of these BSA 14000 SHP-D super high pressure pumps and

the “normal” BSA 14000 HP-D high pressure concrete pump from the test phase to form one

pump station. The machines are around 70 m from the centre of the building tower. The super

high pressure pumps are driven by series produced 470 kW Caterpillar diesel engines.

Different concrete mixture breakdowns

To keep the measurements of the decks and bearing walls as low as possible, and to be

able to carry the increasing loads as height increases, only concretes with high compressive

strength are being used on Dubai’s most spectacular high-rise construction site. According

to the original plans, the distribution of the individual concrete mixture breakdowns was

as follows:

– base plate: C80A (maximum particle size 20 mm)

– Up to level 26 (height 95 m) for the walls: C80A (maximum particle size 20 mm)

– Up to level 126 (height 452 m) for the walls: C80 (maximum particle size 14 mm)

– Up to level 154 (height 570 m) for the walls: C60

– Concrete with compressive strength C50 is required for creating the decks of all sto-

reys.

Although concrete class C80A with 20 mm maximum particle size was originally only

intended for installation up to 95 m height (level 26), this concrete was pumped with a 50

cm spread and a w/c value of 0.3 to a height of 352 m (level 100) with a slightly modified

mixture breakdown. For this height and this material, the concrete pressure during rod

side operation was just 150 bar at 30 m 3 /h.

Costs saved with maximum particle size

There were two main reasons for keeping the mixture breakdown. On the one hand,

all those responsible were pleasantly surprised by how easily the concrete pumps were

able to pump this material even beyond the 300 m mark. On the other hand, there were

clear cost advantages. This is because significantly less cement and fines are required

for concrete with a maximum particle size of 20 mm than for a concrete mixture with a

maximum aggregate particle size of 14 mm.

Although a compressive strength of “just” 80 N/mm 2 was prescribed for this concrete,

later measurements often indicated a strength of over 100 N/mm 2 . This high-strength

concrete contains around 20 different additives, which influence, amongst other things,

the flowability and the setting behaviour.

DNI BETONU 2008

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