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Machines, Equipments and Systems for Tunnel Construction

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Can travel on rails and is specially designed for use intunnels: Rail Concrete UnitRCU-702

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High pressure concrete pumps for extreme heights and distances

Putzmeister has gone beyond the boundsof possibility time and time again byusing more powerful concrete pumpsand intelligent placing systems for tunnelconstruction.In 1994, during the construction of ahydro-power station in Northern Italy itwas thus possible to achieve the worldrecord in covering a height of 532 m withjust one pump. The effective concretepressure at that time was 18.5 MPa(2683 psi). At a construction site in Le Refrain,France, Putzmeister achieved the worldrecord in long-distance concrete convey-ing of 2015 m with the BSA 14000 HP-D.In many such cases, pumping is thequickest and most economical solutioncompared to the alternative methods ofconcrete placing using track vehicles,pneumatic conveying, step-by-steppumping over short distances, and/orcombined means of transport whichPutzmeister also offers where appropr-iate.What matters is that the solution offeredis the right one for the customer. This isensured by our highly qualified engin-eers who base their recommendations onthe know-how gained through their wide practical experience.Our pump and system technology can beapplied to the most different operationsup to 220 m3 and 40 MPa (5801 psi).

Here are some examples:■ Smaller high pressure pumps for

conveying fine slurries and materialswith a grain size up to 32 mm. Thecompact pump is equipped with a S-transfer tube and is predominantlyused for pumping shotcrete andmortar.

■ Pumps with ball valve technology areused for mortar with a grain size of 8 mm. Pressures of up to 13 MPa(1885 psi) are obtained here, makingit possible to pump mortar over largedistances.

World-record for high-rise pumping – 532 m in Italy

Concrete delivery into the ring space

Series BST 2100 concrete pump for record conveying at Lago del Garda/Italy

Jumbo trough for large amounts of concrete

The attached Twistip unit, which can be pivoted to the side, connects the pipeline of the M 24-4 to the holes in the side of the formwork

Modified truck-mounted concrete pumpscan be used in low tunnels and are there-fore the ideal equipment for concretingmany tunnel cross-sections.

The M 24 truck-mounted concrete pumpcan, for example, also be fitted with anelectric drive for the concrete pump anda Twistip unit, which then ensures thatthe end hose is suitably connected to thetunnel formwork.

Special truck-mounted concrete pumpsfor tunnel operation

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■ Supplementary components such asmixers and silos for the suction sideof a plant

■ High pressure delivery lines withcheck valves for the delivery side of aplant

With delivery rates of over 100 m3/h(depending on the core pump fitted),concreting work can be carried out up toa height of 24 m. The maximum verticalreach is nearly 20 m. The 360° rotationof the Twistip allows any concretingposition.

Putzmeister concrete pumps even master extrem-ely stiff concrete

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Tunnel formwork distributor TSV for different tunnel cross-sections

This rail-mounted hydraulically-drivenplacing system is recommended for con-tinuous backfilling along tunnel form-work.

Depending on the model flexible scis-sors pipes make it possible to move 12 m forwards without having to openthe pipeline. The distributor is locked inthe working position by hydraulicallyactuated clamps. Every formworkconnection piece can now be reached atthe exact position by the telescopic plac-ing arm as it is moved axially. Concretingis carried out from bottom to top.

When the pre-set maximum pressure isreached, the distributor lifts up automat-ically and prevents damage which couldbe caused by over-pressure. This isessential for the long-distance conveyingof concrete from above ground.

Specially compact plant variants areavailable for working in extremely lowheights in combination with portal form-work.

The overpressure automatic device of the tunnelformwork distributor

Compact tunnel concrete distributor TSV 2-4 for mounting on a waggon

Portal formwork with mobile tunnel formworkdistributor

TSV in 30 m long 4.5 m diameter tunnel form-work. It is hydraulically propelled and lengthcompensation of the delivery line is carried outwith the scissors’ pipe.

World record in long-distance concrete conveying (1997): 2015 m

The TSV 3-6 form work distributor can be adapted infinitely variably to tunnel diameters of 3 – 6 m. The scissors pipe allows concreting progress of 12 m without the TSV having to be moved.

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Clean and safe conveying of large amounts of muck by using pumps

The way Putzmeister has mastered theconveying technology for high densitysolids and the experience it has gainedfrom more than 100 tunnel constructionprojects, make the company the rightpartner for complete solutions when con-veying muck out of tunnels.

In addition to the extensive consultancyoffered, machines such as the driveunits, crushing and sorting plants, con-veying belts, screens, mixing troughs,high performance pumps, silos aboveground, etc. are all within the scope ofsupply.

The following examples are representat-ive of the range of technical possibilities:

Eurotunnel from France toEnglandHere approximately 8 million cubic met-res of muck mix were conveyed over adistance of 2000 m and over a height ofalmost 200 m.

Storebelt Tunnel Project(Denmark)■ Maintaining earth and water pressure

up to 0.8 MPa (116 psi) to prevent theinflow of ground water

■ Dumping of muck under atmosphericpressure

■ Transporting the rock mixed with ground water from the rear side of themuck conveying augers into the muck trucks

Auger conveyor with two muck pumps type KOS 1480, Botlek TunnelTransfer of muck in a shaft, construction site in Japan

Transfer of muck to the pump feeding device inthe “open system”

Decompression pump, directly flanged at the earth pressure-balanced tunnel boring machine (EPB-TBM) in the “closed system”

Muck pumping “closed system” in pipe jacking“Closed system” muck removal

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Sewage tunnels in JapanWater drains and sewers can be built bypipe jacking in regions of the earth withsoft ground and rock, such as for ex-ample, in Japan. This requires:

■ Muck-removal in narrow sewers,and/or tunnel cross-sections

■ Simple adapting of the transportengineering to the alternating condit-ions in-situ, such as, for example,different shaft depths

Road tunnel with large cross-section in JapanOver 30 Putzmeister decompressionexcavation pumps have been supplied toJapan in the last few years. The reasonfor this is the high level of efficiency forconveying the excavated material, as wellas maximum safety for the structure andtunnel personnel.

Sewage tunnels in ThailandWith regard to the construction of a newsewage tunnel in Bangkok the muck-removal pump technology in a “closedsystem“ is applied on more than 10 con-struction sites. The muck removal tech-nique offers a great deal of safety for thepipe driving speed and at the same timemore simplified logistics for the removalof earth material.

Botlek tunnel in the NetherlandsTwo Putzmeister decompression pumpstransported 300 m3/h sand with foam andpolymers behind the gantry and guarant-eed a clean and safety job site.

London Heathrow tunnelTwo Putzmeister single-piston decom-pression pumps re-moved 200 m3/h ofuntreated loamy soilfrom the shield areasupported by com-

The compact, powerful muck removal pump forextremely small tunnel cross-sections MPT 40

pressed air. This prevented the groundfrom subsiding and the loamy soil was

not contaminated byauxiliary fluids, suchas bentonite or poly-mers.

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Engineering for every kind of mortar injection work

Depending on rock, construction methodand time plan, different machines for theinjection of mortar are used in tunnelconstruction. Putzmeister’s programmeincludes everything from the smallestsingle machine to fill anchor holes,worm pumps for low pressure work topiston pumps for pressures up to 10MPa (1450 psi).

In combination with important accessor-ies such as turbo mixers, high pressurevalves, high pressure rotor distributors,special delivery lines, auger conveyors,flow meters, pressure gauges, etc. plantscan be individually arranged for the mostadvanced methods.

TRIA, i.e. continuous ring space fillingfor tubbing, is often used behind the tun-nelling machine.

Bentonite mixing and pumping plant in Singapore

S 5 small injection pump with plate mixer

Space-saving installation of two KOV 550 DUO located underneath the 6 m3 trough in Singapore forTubbing Ring Space Injection

Compact injection plant directly below the continuous mixer of the silo for refurbishing work in Paris BQT 20 Rotor pumps for continuous ring space injection and injection performances up to 20 m3/h and pump

Features of the HSP 1030

■ Output: up to 7m3/h■ Delivery pressure: up to 6 MPa

(870 psi)■ Intake and delivery valves can be

flanged on in a modular fashion■ Delivery piston with double lip for

optimum suction■ Easy to clean

Single-cylinder piston pump HSP 1030For the annular gap injection, Putzmeisterhas developed the HSP 1030 modelsingle-cylinder piston pumps whichwork independently of each other andhave their pressure and suction cyclescontrolled by seat valves. The HSP 1030pumps can be additionally equipped witha volume measuring feature to allow thevolume of injection mortar to be precise-ly determined. They are easy to clean andhave favourable assembly properties forinstallation in even narrow tunnel cross-sections, thanks to the rotating pumphead. The HSP 1030 can be combinedwith other pumps for various require-ments and numbers of injection points.

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The wet spraying method is becoming more and more popular in tunnel construction

The specific benefits of the wet-sprayingconcreting process are demonstrated intunnelling: less spray mist, little rebound,low energy requirements and comparat-ively low installation effort.

During the wet-spraying process, theaccelerator and compressed air are reg-ulated, combined with the pumping con-crete and sprayed. The upper limit for thegrain size of the concrete lies at approx.8 mm. For smaller jobs, the spray nozzleis handled manually; when high outputsare required, machines are used to helpmanipulation.

There are three types of machines for wetspraying:

■ Attachable machines for existing car-riers, such as shovel loader hydraulicexcavators for use with a stationarypump BSA 1002

■ Manipulators and concrete pumpsmounted on truck chassis for flexibleuse at frequently changing construct-ion sites, type WKF

■ Shotcrete manipulator Sika®-PM 500for concrete outputs upto 30 m3/h forheights and distances up to 14 m

All machines are equipped with the prov-en S-transfer tube.

Sika®-PM407 P

Sika®-PM702 E

Wet sprayed concrete in tunnel construction withBSA 1002 Multi and Sika®-PM 500

Concrete spraying made simple, secure and convenient with the high performance manipulator Sika®-PM 500

Sika®-PM500

S-tube pump

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Towards an economical comprehensive plant – developed with a system

The economic planning and timely ex-ecution of large tunnel construction pro-jects requires the optimum combinationof a variety of machines with a host ofKnow-How and Service components.The command of the technology for con-veying concrete, mortar and high-densitysolids, and the precise and comprehens-ive knowledge of other machines andmethods in tunnel construction, are avail-able for projects with the most complicat-ed requirements. They are put into pract-ice leading to functional and economicalsolutions in co-operation with the cust-omer.

Innovative machine technology

Multi-purpose accessories

Defined interfaces for PM components to further machine technology

Engineering, know-how gained from many projects on large construction sites and in tunnel construction

Reliable After Sales service

Quick parts service

Plant-specific customer training at works or on site

Co-ordinated acquisition and handling of business

Requirementanalysis

Concept and initial quotations

Detailed preparation ofquotation variant

Refining process – leading to the contract award

Development,construction,manufacture and assembly

Field simulati-on on plantteststand at theworks (e.g. hy-draulics, sens-ory analysis,control)

Supply, assembly andsetting up

Final testing and beginning of operation

Project accompani-ment in-situand feedbackfor furtherdevelop-ment

The partners on the Putzmeister side areproject engineers who are qualified toco-ordinate the elements (components)and tasks starting from an analysis of therequirements to the conclusion of theproject, and who ensure that everythingis carried out smoothly. Successful con-tributions to large projects all over theworld are our best references – such as,for example:

■ The Eurotunnel from France to England

■ The Storebelt tunnel project in Denmark

■ Many kilometres of tunnels in Japan

■ Tunnel construction for power stations in Riva del Garda, Italy

■ Metro construction in Madrid,Barcelona, Bologna, Seville, Gijon and Lisbon

■ Sewage tunnels in Shanghai andBangkok

■ Rail and road tunnel in London, Tokyo, Madrid, Leon and San Lorenzo

Putzmeister Concrete Pumps GmbHMax-Eyth-Str. 10 · 72631 Aichtal /GermanyP.O.Box 2152 · 72629 Aichtal /GermanyTel. +49 (7127) 599-0 · Fax +49 (7127) 599-520E-Mail: pmw@pmw.de · www.putzmeister.com

The Putzmeister Group Concrete Technology PCT · Mortar Technology PMTPipe Technology PPT · Water Technology PWTIndustrial Technology PIT · Belt Technology PBTUnderground Technology PUC

Right to make technical amendments reserved© by Putzmeister Concrete Pumps GmbH 2009All rights reserved · Printed in Germany(10903Sc)