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A K H L S P E C I A L R E P O R T

T H E 2 0 1 1 D E F I N I T I V E G U I D E T O T H E

G L O B A L C O N C R E T E C O N S T R U C T I O N S E C T O R

A C R A D L E - T O - G R A V E G U I D E S P A N N I N G

C O N C R E T E P R O D U C T I O N , A P P L I C A T I O N S

A N D E N D - O F - L I F E D E C O M M I S S I O N I N G

I N T E R N A T I O N A LC O N C R E T E

C O N S T R U C T I O N

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International Construction(USPS No: 021-895)is published monthly by KHL Group anddistributed in the US by DSW, 75 Aberdeen Rd,Emigsville, PA 17318-0437. Periodicals postagepaid at Emigsville, PA. Postmaster: send addresschanges to International Construction,PO Box 437, Emigsville PA 17318-0437.

ISSN No: 0020-6415 USPS No: 021-895 Copyright KHL Group 2011

3internationalconcreteconstruction 2011

The paper in this magazine originates from timber thatis sourced from sustainable forests, managed to strictenvironmental, social, and economic standards. Themanufacturing mill has both FSC & PEFC certification,

and also ISO9001 and ISO14001 accreditation.

T

he global concrete construction industry had a mixed time

in 2010. On the one hand there were countries that chargedahead China is an obvious example but the +7.7% increasein Indias cement production also shows that there is more than oneAsian tiger that can roar. On the other hand, markets like Europe andthe US continued to fall last year, and are only now showing signs ofstabilisation.

But despite the mixed outlook last year, the industry clearly grew.Global cement production rose +10% to 3.3 billion tonnes, and thatwould suggest that something like 16 billion tonnes of concrete wasput in place around the world. As the articles in this years edition ofInternational Concrete

Construction illustrate, there are plenty of challenges besides theeconomic ones for the industry to deal with. The enormous versatilityof concrete sees it used more widely and in more applications than any

other construction material, but this also means a lot is demand of itin use, but also in the construction phase.A common theme in this years Special Report on the industry is how

important efficiency is in the industry. Whether it is the developmentof new mixing plants that are easy and quick to set up, to formworksystems to help build complex structures, contractors are asking forquicker solutions and also greater safety.

Chris Sleight

Editor





3/9

INSIDE

Editor Chris Sleight BEng (Hons)e-mail: [email protected] tel: +44 (0)1892 786205Deputy Editor Helen Wrighte-mail: [email protected] tel: +44 (0)1892 786209Editorial Director Paul Marsden BScEditorial Team Lindsey Anderson, Clarise

Arduz, Alex Dahm, Lindsay Gale, SandyGuthrie, Maria Hadlow, Cristin Peters,Murray Pollok, D.Ann Shiffler, Euan Youdale

Advertisement Manager Alister Williamse-mail: [email protected] tel: +44 (0)1892 786223Corporate Sales David Stowee-mail: [email protected] tel: +44 (0)1892 786217

Area Sales Lynn CollettProduction & Circulation DirectorSaara RootesProduction Manager

Ross Dicksone-mail: [email protected] tel: +44 (0)1892 786245Design Manager Jeff GilbertDesigner Gary BrinklowDisplay Production AssistantPippa Smithe-mail: [email protected] tel: +44 (0)1892 786207Financial Controller Paul BakerFinancial AssistantGillian MartinCredit Control Josephine Daye-mail: [email protected] tel: +44 (0)1892 786250Office & Bookshop Sales ManagerKaty Storvike-mail: [email protected] tel: +44 (0)1892 786201Business Development DirectorPeter WatkinsonMarketing ManagerJames Moscickie-mail: [email protected] tel: +44 (0)1892 786229Circulation ManagerTheresa Foxe-mail: [email protected] tel: +44 (0)1892 786238Publisher James King

International Concrete ConstructionPrice:

100 US$ 160 120

MARKET OVERVIEW 7After a heavy fall in 2009, the global market forconcrete and cement stabilised in 2010, although it wasa case of emerging markets enjoying growth, while moremature parts of the world still struggled. Chris Sleightreports.

EXTRACTION 11The race is on to increase production at quarries aroundthe world, and operators are seeking to avoid downtimeby upgrading their fleets with the most efficient andreliable machines available.

MIXING & PRODUCTION 21Increasing durability is the name of the game for

individual mixer components, while the quest forplant manufactures is to make their products as easy totransport and set up as possible.

PLACING 25Advances in concrete placing technology are allowingmore complex projects to be executed, thanks to greaterreach with placing booms, combined with equipmentfootprints that are both compact and flexible.

FORMING 31Formwork systems not only have to be able to deliverever more complex structures, they also have tocontribute to efficiency and safety on site protectingworkeres from the risk of falls, as well as from harshweeather conditions.

PAVING 39Paving with concrete is not as widespread as the use ofasphalt, but the rising cost of bitumen, coupled withthe versatility of modern slipformers be they highwayclass pavers or curb & gutter machines may bechanging opinions.

END OF LIFE 45Although tempered by the global recession, thedemolition industry continues to show a preference forbigger and bigger equipment, while recycling waste forprofit remains a growing business area.

EQUIPMENT LISTINGS 53 TRAILER PUMPS 54

TRUCK-MOUNTED PLACING BOOMS 58

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4/9internationalconcreteconstruction 2011 7

MARKET REVIEWConcrete recovery

ConcreterecoveryAfter a heavy fall in 2009, the global market for concrete and cement stabilised in

2010, although it was a case of emerging markets enjoying growth, while more mature

parts of the world still struggled. Chris Sleight reports.

If 2009 was the year of the recession, 2010 saw stabilisationin the global cement, concrete and aggregates market.In fact, data from Cembureau, the European cement

producers trade association, global production of cement rosein 2010 to 3.3 billion tonnes, up +10% on the 3.0 billiontonnes in 2009.

However, it was far from being a smooth all-round recovery.Developing markets were responsible for the growth, withoutput and consumption slipping in mature parts of the world

like Europe, the US and Japan.China once again dominated the globalcement production landscape in 2010,accounting for 56.1% of global output,or a massive 1.85 billion tonnes. In 2009the country produced 1.64 billion tonnesof cement, so the increase was +13.1% or210 million tonnes. This was a massiveincrease about equivalent to the totalannual output of the next largest cementproducer in the world, India.Another way of looking at this is that

global cement production grew by 300million tonnes last year, so Chinas

increased output represented about two-thirds of the rise.

It was not quite as clear-cut as thisof course, with many other developingmarkets growing, and some of theseglobal gains being offset by falls inmature markets. And India also saw a strong rise in

cement output last year, with productionrising +7.7% about 15 million tonnes to 208 million tonnes.

But the world economy was far frombuoyant in 2010, and the sluggish

recovery of many mature markets wasreflected in their cement production. Japanese output was down -11.2% to53 million tonnes for example, while inthe US output fell -8.2% to 66 milliontonnes.

Worlds 20 largest cement, aggregate & concrete producers

Rank Company Country 2010 2010 2010 2010revenues cement & aggregate ready mixed

clinker sales sales concrete sales(US$ million) (million tonnes) (million tonnes) (million m3)

1 1(0) Lafarge France 21443 135.7 193.2 34.0

2 2(0) Holcim Switzerland 20807 136.7 157.9 45.9

3 3(0) Heidelberg Cement Germany 15598 78.4 239.7 35.0

4 4(0) Cemex Mexico 14069 96.1 123.2

5 5(0) CRH (materials division only) Ireland 9392 13.2 52.2 15.0

6 6(0) Taiheiyo Cement Japan 8274 14.8

7 12(5) Votorantim Cimentos Brazil 78008 9(1) China national China 6536

materials company (Sinoma)

9 7(-2) Italcementi Italy 6354 54.4 36.7 11.4

10 13(3) Anhui Conch Cement China 5098

11 8(-3) Tong Yang South Korea 4264

12 10(-2) Boral Australia 4223

13 11(-2) Buzzi Unicem Italy 3512 26.6 10.7 14.4

14 18(4) Taiwan Cement Taiwan 3370

15 NEW BBMG China 3250

16 NEW Ultra Tech Cement India 3058

17 14(-3) Cimpor Portugal 2969 28.3 12.8 6.7

18 19(1) Inversiones Argos Colombia 2920

19 16(-3) Vicat Group France 2671 16.2 20.8 7.7

20 17(-3) Vulcan Materials US 2406 0.8 147.6 3.2

Total 148013 601 995 173

Last year 142515

Change 4%


5/911internationalconcreteconstruction 2011

EXTRACTIONMeeting global demand

>

The race is on to increase

production at quarries

around the world, and

operators are seeking

to avoid downtime by

upgrading their fleets with

the most efficient and

reliable machines available.

Helen Wright reports.

introduced as standard on some new equipment ranges. Te latestmachines or use in quarrying applications also eature improvedtransmissions and hydraulics as well as other technology.

Te increased automation o quarrying machinery is another

major trend. For example, automatic traction control (AC) isa common eature in the latest articulated dump truck (AD)launches rom major manuacturers like Komatsu, Caterpillar,Volvo, Bell and John Deere, erex and Doosan/Moxy.

Komatsu America, or example, has launched a new, emissions-compliant AD which has been designed with increasedautomation, security and uel ef ciency in mind. Te HM300-3is powered by a 325 hp (242 kW) Komatsu SAA6D125E-6 ier4 Interim and Stage IIIB engine and is capable o hauling up toa 28 tonne payload.

Te machine eatures both Komatsu s traction control system(K-CS), which automatically provides optimum tractionor dierent ground conditions, as well as KOMRAX eet

monitoring technology as standard. Tis is a wireless systemwhich sends machine operating inormation such as daily uelconsumption, location and operation hours to a secure website.

Meeting globaldemandAs daily production targets at quarries increase to meetrising global demand or construction materials, quarryoperators are modernising their eets with the aim o

increasing ef ciency and there is no shortage new equipmentto choose rom.A big driver behind this years string o equipment launches or

the US and European markets has been the new US Interim ier4 regulations on exhaust emissions, and the equivalent Europeanlegislation, Stage IIIB.

Te rst set o laws that came into orce at the start o the yearapplied to 130 kW to 560 kW diesel engines, and manuacturers

have responded by launching new generations o heavy machinerytted with new uel-ef cient and emissions-compliant engines.

Security and ef ciency are also increasingly at the oreronto the latest designs, with remote monitoring systems being

Hinkle Contracting has installed Major

Wires Flex-Mat 3 Modular screen

system to improve efficiency at its Lake

Cumberland Stone quarry in the US.

Caterpillar has launched three new ATDs the 735B, 740B

and 740B EJ.



MIXING & PRODUCTIONSet-up considerations

Set-up considerationsIncreasing durability is the name of thegame for individual mixer components,

while the quest for plant manufactures

is to make their products as easy to

transport and set up as possible.

Given that construction projects are temporary activities,it is easy to understand why contractors look for mixingand batching plants that are easy to transport, set-up and

dismantle. A plant may have dozens of locations over the courseof its life, and the times when it is in transit or inoperable meansmoney is being lost.A good example of how modern batching plant suppliers are

tackling these issues comes from Rapid International and one ofits newest products, the Rapidbatch 120 mobile batching plant,which features a twin shaft mixer capable of producing up to120 m3 per hour in 3 m3 batches.

The entire unit is installed in the trailer section of a 17 m truck

and can be erected by a single crane lift. Export sales manager Adrian Pearson said, Installation only requires compactedground, so the unit can be used almost anywhere for onsiteconstruction projects. As a result of this, the unit is generatinga lot of interest in Russia with road contractors.

A contractor can pave a 10 km stretch and then easily movethe batching plant for the next section. With road projects of400 km or more, the Rapidbatch 120 is in its element, he said.Another benefit is that no planning permission is required withthis plant.

The Rapidbatch 120 is equipped with the companys Rapid Jetwash high pressure water nozzles that complete a cleaning

cycle of the Twin Shaft mixer in just three minutes at pressuresof 138 Bar.

As well as road projects, the Rapidbatch 120 is also ideallysuited to wind farm projects, ports and airport construction,bridge building, car parks and many other applications, saidMr Pearson.

In a similar vein, SBM Mineral Processings Euromix 3000mobile concrete mixing plant features a modular design sothat it can be adapted to meet customer demands. Users canconfigure the performance to match specifications preciselyusing interchangeable components from the companys differentmixing plants.

Rapid Internationals

Rapidbatch 120 mobile

batching plant features a

twin shaft mixer capable

of producing up to

120 m3 per hour in 3 m3

batches. The entire

unit is installed in

the trailer section

of a 17 m truck and

can be erected by asingle crane lift.

SBMs Euromix 3000 mobile concrete mixing plant features

a modular design so that it can be adapted to meet customer

demands. Users can configure the performance to match

specifications precisely using interchangeable components

from the companys different mixing plants.



PLACINGPlacing sophistication

Anumber o case studies over the last year have illustratedhow advanced and fexible concrete placing systems canmake a real dierence to how quickly, saely and e ciently

construction projects can be executed.Putzmeisters large boom team began working on a project to

concrete a narrow motorway junction in Germany in August2009 a job which demanded the maximum reach o someo the companys largest booms. The work at the Neuahrnjunction, where the A9 and the A92 meet north o Munich, isset to be completed in October, 2011.

Two large Putzmeister boom concrete pumps, the M 58-5and M 62-6, were drated in by contractor Hentschke Bau tohelp with replacing the current, single-lane exit with a lyoverthat channels a two-lane carriageway rom the A92 to the A9towards the south.

For the irst 120 m section o the lyover, a total o 2000 m3

o concrete was placed over a 24 hour period enough or theentire cross-section o the structure.

The second section a road segment that is 80 m long willbe completed later this year and the complete superstructure willcontain 2300 m3 o concrete.

The high level o lexibility o the machines booms were keycriteria in their selection or the task Putzmeister claims theM 62-6 and the M 58-5 have the longest horizontal reach o

any pump in Bavaria. The M 58-5 eatures a ive section RZolding boom with a maximum vertical reach o 57.6 m, whilethe larger M 62-6 eatures a six section RZ boom with a totalvertical reach o 61.1 m.

Each o the two truck-mounted concrete pumps used the ullextent o their horizontal reach in order to pump concrete tothe 12 m-high placement site. All the while, traic was lowingreely on the circular paths o the exits and under the structure.

Dam facingHaving gained experience using a Power Curbers 5700-C toorm electrical conduit sections on South Aricas Gautrainhigh-speed rail project last year, this year saw Gautang provincesExotic Concrete apply the machine to the Bedord Dam projectnear Ladysmith. The dam, which sits 1700 m above sea level,orms the upper reservoir or the Ingula Pumped Storage scheme.

The project comprises a 50 m high, 577 m long concreteacing supported by a rock illed embankment. The size o thedam is staggering, requiring 982000 m3 o rock ill and another27000 m3 o conventional concrete. Behind these walls, thereservoir holds 22 million m3 o water.

Beginning at the base, Exotic poured a 400 mm x 760 mm

trapezoidal curb the length o the dam using the Power Curberscurb & gutter machine. Behind the curb, rock backill wasplaced and compacted. Following the backill completion, the5700-Super-B, running on the irst pass, poured a second curbwhich partially overlapped the irst.

And so it continued. Ater each section o wall was slipormed,

Placing

sophistication

Putzmeisters M 58-5

concrete pump at

work on the Neufahrn

junction in Munich,

Germany.

Advances in concrete placing technology are allowing

more complex projects to be executed.



PAVINGPaving productivity

In Australia, a road safety project called for an unusuallylarge concrete barrier to be slipformed at the bottom of thewinding Bulli Pass near Sydney.

Concerned with the potential for trucks losing control at thebottom of the road, local authorities decided to build a 2 mhigh wall, anchored to a 1 m x 1 m footing, resting on 8 m deeppiles. Main contractor BMD Construction sub-contracted thework to Nation Wide Slipforming, which used its Power Curber5700-C-MAX to get the job done quickly and minimise thedisruption from road closures.

Construction Manager Warren Scattergood used the C-MAXslow speed torque hubs to crawl the machine at 300 m to 400mm per minute, allowing for the necessary concrete compactionand vibration in the behemoth mold. Even with the auger

at full speed, a 3500 kg mold attached, and running all ninevibrators I had plenty of horsepower noted Mr Scattergood. Ichecked the engine stats while paving and was running at 70%of capacity.

In the US meanwhile, Brooklyn, Iowa-based paving contractorused its 2004 model GHP-2800 Gomaco slipform paver with anew 5400 series mold and bar inserter for a 12.5 mile (20.1 km)stretch of Highway 30 in Iowa. The company also upgraded to aG22 controller and new software to help ensure it met the statesexacting requirements for surface smoothness.

Two pan-mounted Gomaco Smoothness Indicator (GSI) unitswere used to monitor the paving results, which were recorded onthe G22. After three days, with the help of Gomaco engineers,the software and paver were fine tuned.

Gomaco controls engineering manager Mark Brenner said,With this new software we have one-touch calibration for theelevation threshold. The operator holds a button down and hasinstant feedback from any movement of the leg displayed onthe G22s screen.

"One person is making the adjustments from on top of thepaver. We have eliminated an extra person from the set-upprocedure. When that is done, the operator can then set thepaver up to pave either string line or stringless, and using the

green, yellow or red deviation meters go through the process ofhigh-definition tuning. Wirtgen meanwhile has launched its Autopilot 3D control

Paving with concrete is not as widespread as the use of asphalt, but the rising cost ofbitumen, coupled with the versatility of modern slipformers may be changing opinions.

Paving productivity

One of Gomacos latest pavers is this model,

which is designed to handle sharp radiuses.

Minnich has introduced wireless power rotation on

machine-mounted dowel pin drills.


9/9i t ti l t t ti 201154

EQUIPMENT LISTINGTrailer pumps

Manufacturer Model Maximum Concrete Delivery Cylinder Engine

Pumping Capacity Pressure Diameter Stroke Power

(m3 ) (bar) (mm) (mm) (kW)

Bunker B100 0.25 12 n/s n/s 18.5

Bunker B100XP 0.25 12 n/s n/s 37

Bunker B100 S 0.25 25 n/s n/s 38 Aliva (Sika) AL-246 (shotcrete) 4 n/s n/s n/s 3

MECBO Getto T400 7 50 120 400 7

Aliva (Sika) AL-252 (shotcrete) 8 n/s n/s n/s 5


MECBO Getto P2600 11 50 120 600 11

Reed B20 15 114 102 914 82

Reed B20HP 15 145 102 914 82

MECBO Getto P2800 15 50 120 800 15



Reed A30 23 62 127 762 61

Reed A30HP 23 62 127 762 61

Aliva (Sika) AL-278 (shotcrete) 23 70 150 600 37

Schwing SP 305 23 43 125 750 35

MECBO Car P5.25 25 60 150 900 30

Putzmeister BSA1003 D GFK 28 80 150 1000 47

Sermac SCC30 30 126 150 1000 n/s

CIFA PC307 30 70 176 1000 n/s

CIFA 6 series 30 70 176 1000 43

Reed A40HP 31 81 152 762 61

Hydroseal Valve Micro 35 70 150 n/s 43

Schwing SP 500 35 76 150 1000 54

Reed B50 38 94 152 914 82

Reed C50S 38 114 152 1067 119

Reed B50HP 38 94 152 914 97

Reed C50SS 41 138 152 1067 164

Sermac SCC45 44 87 180 1000 n/sReed B60 46 81 152 914 82

Putzmeister BSA 1005-E 47 55 180 1000 45

Zoomlion - Puyuan HBT40RS 48 50 180 1200 48.6

Zoomlion - Puyuan HBT40.10.60RS 49 50 180 1200 60

Hydroseal Valve Midi 50 70 152 1000 74

MECBO Car P4.50 50 50 180 1400 75

CIFA PC506 52 57 176 1000 n/s

Schwing SP 1400 52 63 180 1400 100

Reed B70 54 69 178 914 97

Reed C70S 54 84 178 1067 119

Putzmeister BSA 1005-D GFK 54 71 180 1000 61

Schwing SP 750 54 76 180 1000 75

Putzmeister BSA 1405 E 55 106 200 1400 75

Reed C70SS 56 102 178 1067 164

Sermac SCM 60C 57 143 180 1600 n/s

Sermac SCM 60HP 58 169 180 1600 n/s

Zoomlion - Puyuan HBT60.13.112RSC 65 130 200 1710 112

Sermac SCM65CHP 65 100 200 1600 n/s

MECBO Car P4.65 65 70 180 1400 90

Schwing SP 4800 66 243 180 2000 330

Reed C90S 69 102 178 1067 164

CIFA 7 series 70 150 176 1500 n/s

Zoomlion - Puyuan HBT60.13.90RSC 70 130 200 1800 90

Sermac SCM 70C 70 116 200 1600 n/s

Putzmeister BSA 14000 SHP D 71 320 180 2100 470

Putzmeister BSA 2107 HP-E 71 220 200 2100 200

Putzmeister BSA 1407-D 71 106 200 1400 115

Zoomlion - Puyuan HBT60.16.110SE 72 160 200 1800 110

Zoomlion - Puyuan HBT80.16.110SC 72 160 200 1800 110

Sermac SCM 70HP 72 137 200 1600 n/s

Schwing SP 1800 73 108 200 1600 126

Zoomlion - Puyuan HBT60RS 75 125 200 1650 80

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