Construction Machinery ME July 2018

ISSUE 81 JULY 2018

PLUS

CCESS SPEED oF aAc ceSS

R aPid ecRet S e h t S e ShaR ceSS c U S S t i of

A nCE M r o F r E P P U D E PUMP ncRete

o MobiLe c keRS Reach PUMP M a highS foR new

t L I U B h g U to

bobcat

at s e n e c s the d y n r i o h t e c b a f u ea m es yo e k s ’ a t t s E i l M CM ecia p s t c a p the com

CONTENTS JULY 2018 6_News The latest news from across the region and further afield.

14_oN a comeBack Chinese manufacturers use the market conditions to push their kit as not merely cost-effective solutions but qaulity products with full support.

18_speed of access Rapid Access leverages its extensive fleet and regional presence for new projects and technologies, as it introduces new virtual reality simulator.

r e w o raw p el 24_ New R The latest

e a se s

d of m the worl releases fro

eN 28_Top T

12 SpoTTeD nD in ponelpa erfroms a

ry.

n machine

constructio

n men and

er heat o f the summ

cts o

ng the effe

si Tips for ea

18

12

Terex cra t powerplan tall task in wer cooling to project

14

24

machines.

BcaT i T l ik e B o

s. quality rule d ctory where l fa i A E u M B E s _ of it 30 E on a tour t takes CMM ca l al sm e h T

Nce eRfoRm a bility and service. p p u d e lia ers talk of re 36_ pump e pump mak et cr n co d te n Truck-mou ul a iNg foRm N N i w ’s d season. illiam w s into secon d ce N ra s a u o B h ower 40_Jc nt and F1 p t gia of equipmen Partnership

36

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2

EDITORIAL JULY 2018

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

Quality Matters Step onto the floor of the Bobcat factory at Dobris in the Czech Republic and, amid the din and hum of the laser cutters, the computerised benders, the robotic welding arms, the automated paint shops and the men going hammer and tongs about their business – quite literally – you hear one word repeated louder and clearer than every ambient noise: quality.

That word is being repeated by the senior management who are taking me on a tour of the facility, to show how the Middle East’s favourite skid-steer loaders are made. The process is an exemplar of exactitude. Checks and rechecks characterise almost every station in the long assembly line and nothing is left to chance. At the most critical stages – the end of the welding lines, the transmission assembly and the painting process – the components are subjected to rigorous quality controls.

The miracle is that almost everything passes the tough tests. Or make that a marvel of the manufacturing process, instead of a miracle.

At the end of the process, when a finished unit rolls off the line, it gets a final quality once over. And what a once over it is! There is a 60-point check list of standards that the finished product must meet, which includes a session of performing outdoors in a simulated job-site. And they do this for every single machine that is produced.

No wonder, then, that the machines perform so brilliantly at our tough work sites in this region and in our demanding conditions.

Once you see them being produced and get first-hand knowledge of the dedication behind the process, it’s easy to see why Bobcat commands more than 50% of the skid-steer market here in the Middle East and

its machines have acquired such legendary status. Quality does indeed matter.

And the theme of quality runs through the other stories of this entire issue. Whether it’s truck-mounted concrete pump makers or powered access service providers – or even Chinese manufacturers who have not hitherto been known for quality in their offerings – everyone is striving to provide the best. And in both products and services.

The market is still not in the pink of health and in such a scenario, customers plumb for the best as a way to mitigate risk and to be able to realise residual value, should they have to liquidate assets. Realising this, manufacturers are going in with a very holistic approach to quality, not only from a product point of view but also from the service and after-sales perspective. Whether it’s a Zoomlion which is consolidating its operations in the region with a focus on after-sales, or a Rapid Access, which has introduced a new virtual reality training AWP simulator, the heat is on to be the best.

The heat is also on in the peak of summer in our region, so here’s reminding everyone in the sector to be extra careful while working under the scorching midday sun.

SALES ExECuTIvE TOM BROMLEY tom.bromley@cpitrademedia.com +971 4 375 5496 DESIGN ART DIRECTOR SIMON COBON simon.cobon@cpitrademedia.com DESIGNER PERCIVAL MANALAYSAY percival.manalaysay@cpitrademedia.com MARKETING MARKETING MANAGER SHEENA SAPSFORD sheena.sapsford@cpitrademedia.com +971 4 375 5498 CIRCULATION & PRODUCTION DISTRIbuTION MANAGER SUNIL KUMAR sunil.kumar@cpitrademedia.com +971 4 375 5476 PRODuCTION MANAGER VIPIN V. VIJAY vipin.vijay@cpitrademedia.com +971 4 375 5713

WEb DEVELOPMENT MOHAMMAD AwAIS SADIQ SIDDIQUI

FOUNDER DOMINIC DE SOUSA (1959-2015) PRINTED by PRINTwELL PRINTING PRESS LLC PUbLIShED by

Anirban Bagchi Editor, CMME

Licensed by TECOM to registered company, CPI Trade Publishing FZ LLC whose registered office is 207 – 209, Building 3, Dubai Studio City, Dubai, UAE. www.cpitrademedia.com © Copyright 2018 CPI. All rights reserved. while the publishers have made every effort to ensure the accuracy of all information in this magazine, they will not be held responsible for any errors therein.

It fits, but will it do the job?

Oil. There are all kinds of oil made for different purposes. Be sure to use the right one for the job. Volvo premium oils are developed especially for your Volvo machine, helping it to achieve optimal performance in the toughest conditions regardless of temperature.

We spend years of research and testing to produce the parts that make your Volvo deliver the highest productivity and profitability, over and over again.

Stay genuine – Genuine Volvo Parts. volvoce.com

4

ONLINE JULY 2018

MOST POPULAR

ReADeRS’ COMMeNTS

FeATUReD

bIM

ASGC LOOkS TO CLOSe CONSTRUCTION INDUSTRY’S SkILLS GAP

FIFA World Cup 2018 stadiums built with Trimble technology

CONSTRUCTION

Samsung is increasing focus on renewable energy

In Pictures: On site at Deira Islands

Name withheld by request

CONSTRUCTION

Made for the Middle East: Visiting Alstom’s French HQ

RePORT: THe AbU DHAbI COMMeRCIAL MARkeT IN H1 2018

CONSTRUCTION

Majid Al Futtaim sets ambitious sustainability targets for Tilal Al Ghaf

PROPeRTY

Why Dubai’s real estate market is on an upward trajectory

We have heard for a number of years about the importance of getting younger talent into the construction and I support every attempt for ASGC to achieve its goal of “growing workforce on the ‘cutting edge of technological and engineering advancements”.

We’ve seen in the past the industry has lost of its talent whenever there is a change in the economic climate and this is a great initiative to demonstrate that a career in construction is a worthwhile route for local talent.

Feature: How the Founder’s Memorial was built

Really interesting to read: “Landlords who have not adjusted to these evolving market conditions by either adjusting headline rents, upgrading building premises or offering further floor divisions are facing a standoff and losing tenants to better built premises offering flexible terms.”

Hopefully, this means that more landlords are going to realise that they can’t take their tenants for granted. As the property market matures, owners will need to work harder to get tenants and that is a good thing all concerned.

Name withheld by request

Š Terex Cranes 2018. Terex, Demag and Above, Ahead, Always are trademarks of or licensed by Terex Corporation or its subsidiaries.

The new AC 300-6

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To allow for high versatility, the AC 300-6 can be adapted to the needs of a variety of jobs and is the smallest crane in the Demag AC range with a luffing jib.

The HAV and many components are shared with Demag 5-axle cranes — increasing your return on investment and reducing the amount of spare parts you need to have on hand.

Above. Ahead. Always. www.demagmobilecranes.com

S W NE 6

Safety at heightS

Genie’s new secondary GuardinG for lifts

jects, o r p w e n offices, w e n , s e hin around k o new mac o l e ives – w t a month i t s i i n h i t w e ne w what’s n t a n o i G the re SALES RISE AT SkyjACk The industrial

Genie has developed a new

division of

secondary guarding safety system

Linamar Group,

designed to automatically prevent

comprising

a slab scissor lift or vertical mast lift

mainly of access

platform from hitting an object.

manufacturer

Alarm system is designed for Genie

its sales by 38.6%

GS scissors and GR, GRC and QS

for the first

vertical masts, and activates when

quarter of 2018

an obstruction makes contact with

compared to the

an activation whisker mounted

same period last

on the lift’s platform guardrails.

year. Operating

Once activated, it will alert the

earnings were

operator, occupants and ground

up 63.1%, which

personnel of potential hazards. In

Linamar attributed

the standard configuration it will

to increased

have a whisker each mounted on

sales related to

the front and rear of the platform

the acquisition

ALE claims record for Saudi move Global heavy lift and transport specialist ALE has claimed a new world record for moving a 5134t evaporator in Saudi Arabia.

The company said it was contracted to deliver the evaporator, as well as lime filters, steam transformers and a brine manifold, to the Shoaiba Desalination Plant Project near Jeddah. It undertook the transportation project and, with the evaporator, broke the world record for the heaviest object to be transported.

ALE said it first received the items at the plant’s jetty and loaded the evaporator using 186 Generation 3 SPMT axle lines in a 3x2 file 62 configuration.

Various other smaller configurations were used for the other items. These

were then transported over a kilometre to the desalination plant project site.

When they reached the site, ALE had to find a route within the plant, which was full of challenges. To keep removal of obstacles to a minimum, the cargo was modified to pass over fences.

Andrew Spink, GM, ALE Saudi Arabia, said: “This was a complex operation, not only in terms of the pieces involved, but also the logistics of receiving almost 200 axle lines of SPMT and mobilising an experienced transport crew. It was completed successfully within the time constraints all thanks to our team’s flexibility, local expertise and effective co-ordination between the ALE’s Middle East branches.”

The new Genie Lift Guard Contact

Skyjack, increased

Zach Gilmor, Genie product

of MacDon and

manager, Terex AWP, for the

market share

EMEAR region, said: “The Genie

gains and volumes

Lift Guard Contact Alarm system is

for booms and

designed to supplement a trained

telehandlers.

operator’s situational awareness

Sales increased

and provide a secondary layer of

to $397.5m in the

guarding while working at height.”

quarter over the

The system is activated when

same period in

an activation whisker is deflected

2017. The company

by an obstruction, which triggers

said while

a limit switch in the base of the

increased volumes

assembly, stopping all machine

for telehandlers

motion and sounding an alarm

in North America

along with flashing beacons.

pushed sales

Driving and elevating functions will

upward, the

be available to the operator after he

figures were

has acknowledged the activation of

partially offset by

the system and the machine stopping.

changes in foreign

Gilmor added that there will be a

exchange rates.

free-movement zone between the activation whisker and the guardrail, allowing mobility for operators and occupants after the system is activated.

While the system is slated to go into production in late 2018, a retrofit kit will be available for earlier models.

MADE IN ITALY BUILT STRONG TO LAST LONG

K55L www.cifa.com

8

NeWS ROUND-UP JULY 2018

RiyaDh MetRO

alstom conducts initial dynamic tests

New JCB telematics for mixed fleet owners

SADARA, VEOLIA jOIN FOR jUbAIL UTILITIES FACILITy Sadara Chemical Company and Veolia Middle East SAS will jointly build a sustainable central

French engineering major Alstom has

utilities facility in

started initial dynamic tests for the

PlasChem Park,

Riyadh Metro at the project’s Line 4

the industrial park

depot test track in the Saudi Capital.

adjacent to Sadara

on for the past few weeks and include

in Saudi Arabia’s

demonstrations of the performance of

Jubail Industrial

the railway system, from power supply

City II. Sadara

to signalling systems, using trains

and Paris-based

which have already been delivered.

industrial waste

JCB has launched a new version of its LiveLink telematics system, which enables mixed fleet operators to control all of their plant and equipment with one network.

The British equipment heavyweight said the JCB LiveLink is its own telematics system and is used on over 160,000 JCB machines worldwide, with more than 70,000 logins per month. Now these

same remote machine monitoring benefits are available to customers who also operate nonJCB equipment.

The new JCB LiveLink Control Tower system allows fleet owners to seamlessly import fleet data from any telematics system compliant with the Association of Equipment Management Professionals (AEMP) Telematics standard V1.2,

said JCB. All machine information – whether JCB or competitive equipment - can then be displayed and interpreted in one secure, intuitive web portal or integrated into a user’s own IT system. JCB will also provide several Developer Toolkit services to assist with integrating machine data into existing systems and rental or fleet management software.

Alstom said the tests have been going

Chemical Complex

“This test run is a significant milestone

management

for Alstom and for the project. We are

group, Veolia,

proud to conduct the tests in Riyadh in

signed an

order to deliver a state-of-the-art metro

agreement last

to our customer Arriyadh Development

month to build

Authority (ADA) and the inhabitants

the utility plant

and the visitors of Riyadh,” said Didier

with waste

Pfleger, Alstom’s senior VP, MEA.

management

The Riyadh Metro Project, owned by

and waste energy

ADA, has six lines totalling 176km and

facilities.

85 stations. It is being built by the FAST consortium, of which Alstom is a part.

The French giant is supplying a fully integrated metro system for lines 4, 5 and 6, including 69 Metropolis-based trains, Urbalis signalling system, Hesop energy recovery station as well as tracks.

Cat introduCes new wheeled dozer

NEW REGIONAL HEAD AT GRUNDFOS Pump maker Grundfos has appointed Okay Barutcu to head its East Europe, West Asia, Middle East & Africa operations.

Barutcu will be group SVP and regional MD, based in Dubai’s new regional headquarters.

Caterpillar has in troduced a new wheeled bulldozer desig ned for applicatio ns like utility work at mines an d heavy civil co ns tru ction The new Cat 814K fe atures a new, so und-suppressed cab, efficient po wer unit and tra nsmission drive centralised serv , and ice station confi guration to incr machine uptim ea se e and operator pr oductivity. Its new hydraulic fil tration results in cleaner hydraulic oil to increase compo nent life and extends the oil inspectio n requirement by 50%, from 2,000 to 4,000 ho urs.

9

Cat, Al-Bahar go solar for Dubai facility

Caterpillar Middle East and its regional dealer Al-Bahar have jointly completed their first Solar Photovoltaic (PV) Project, which includes design, installation and commissioning of a Grid Tied Solar PV plant, for their regional facility.

According Al-Bahar, the move is expected to provide the Caterpillar Distribution

Services facility with 237MwH of energy yield annually for the next 25 years, assuring it a sustainable and costeffective solution for the facility’s power needs.

The project is inspired by the Shams Dubai initiative by the Dubai Electricity and Water Authority (DEWA), the first smart initiative of

its kind in the emirate for solar energy and part of the authority’s Distributed Renewable Resources Generation programme, which intends to enable the facility to reduce dependency on grid power, said Al-Bahar.

The 138 Kwp plant will cover 1700sqm, which can accommodate 1200 Caterpillar

TADANO PICkS UP glObal MaRket StUDy

MANITEx STAkE

uae amonG fastest GrowinG construction markets

Japan’s Tadano has taken a 14.9% stake in Manitex

Dubai has emerged as one of the fastest growing

the European contribution.

Meanwhile, the UAE is in

International, after purchasing

construction markets in

among the top two fastest

almost three

the world in a study by

growing construction

million shares in

Dutch consulting engineers,

markets in the world in 2018,

the US crane and

Arcadis, which also found

with year-on-year growth

access equipment

North American cities to be

of 10%. Also on the list is the

maker. Tadano

the most expensive globally

Philippines, with Vietnam

said it bought

for construction projects.

and Indonesia making the

2,918,542 Manitex

top five. India, Sweden,

shares for around

Arcadis said San Francisco

South korea, China and the

$32.7m at $11.19

has the highest costs in

Netherlands make up the rest

per share. Tadano

the world for construction

of the top 10 construction

has exercised its

projects at present, followed

markets experiencing

right to appoint

by New york and Hong

the fastest expansion.

a member to the

In a report on the study,

“The relative strength of

Manitex board by

boston coming in fourth

the US dollar is a key factor

designating Ingo

and fifth respectively. With

influencing the positioning

Schiller, president

Philadelphia and Chicago,

of cities in the index this

and CEO, Tadano

North America emerges as

year. The strong dollar

America Corp.

the most expensive region

places North American

in the world to build in with

cities higher in the index

six cities in the top 10. Macau

compared to markets where

joins Hong kong from Asia

the domestic currency is

while London at eighth and

relatively weaker against the

Geneva at tenth make up

greenback,” said the report.

kong, with Toronto and

115Wp Thin Film Solar PV Modules. Cat’s Photovoltaic Module PVT 115 with an efficiency of around 16%, has been utilised for the project, which is the first solar ground installation in Dubai’s JAFZA area, especially for a training centre in the region. In addition to ground installations, the project also includes panels on a 6m high canopy that offers shade for generators.

Four 25kw inverters and one 20kw inverter, offering a total of 120KW AC, are also part of the system.

According to Al-Bahar, the thin film technology has an advantage over other technologies like multi crystalline, as the Cat PVT115 modules generate more energy than competing ones with same power rating.

FMS TECH LAUNCHES GEOFENCING Fleet Management Systems & Technologies has introduced its new Geofencing software for fleet management in the GCC. The new in-vehicle monitoring systems, enables administrators to control a virtual boundary around a specified location and sends alerts when vehicles enter or exit it.

Volvo Penta to offer electric power systems Engine and power products specialist Volvo Penta will provide electric power solutions for both its land and sea-based business areas by 2021.

The Volvo Group company said that as part of this commitment, it has undertaken an organisational restructuring to accelerate the switch towards electrified power. As part of the increased commitment to its electrification investment programme, Volvo Penta has already established an electromobility development and test laboratory at its Swedish headquarters.

“Volvo Penta is embracing the electric transformation and will be at the forefront in delivering compelling business cases to customers using this new technology,” said Björn Ingemanson, president, Volvo Penta.

“We will take a full systems supplier approach helping our customers in the transition to the new technology. This will happen applicationby-application, on the basis that the business case for switching to electric will differ across our many customer segments. This is the start of a long-term transition.”

Volvo Penta will offer both hybrid and all-electric solutions from 2021, with testing and validation already underway on prototypes.

10

NeWS ROUND-UP JULY 2018

kUWait iNteRNatiONal aiRPORt

nft supplies 26 potain tower cranes for new terminal build

JLG introduces its largest hybrid AWP

Powered access specialist JLG has announced the introduction of the H800AJ, its largest hybrid aerial work platform (AWP).

According to the Oshkosh Corporation company, the new model can be operated in electric mode only and also in hybrid mode when conditions get rougher or the batteries need charging. The H800AJ will be available from the summer onwards, initially in the European market, JLG said.

“Hybrid equipment, or urbancompliant product as we call it at JLG, is becoming more and more

GENIE HOSTS DISTRIbUTOR SUMMIT Terex Aerial Work Platforms (AWP), owners of the Genie brand, recently held its distributor summit in Dubai, which was attended by more than 45 of its authorised dealers from the Middle East, South Africa and Russia (MESAR) region. The two-day event focused on latest Genie products, marketing support and tools.

common... There is a clear need for equipment that performs like a diesel, yet emits low emissions and noise,” said Jan-Willem van Wier, senior product marketing manager for JLG in EMEA. “The H800AJ is a one-of-a-kind solution offering our customers best of both worlds. It is suitable for harsh construction work, with the possibility to operate indoor at zero emissions and very little noise.

Our expectations for this product are high as the H800AJ meets the latest environmental requirements and adds to our customers’ bottom lines as the utilisation is so much broader than a regular diesel lift.”

The H800AJ offers a working height of 26.4m, a working outreach of 16.45m and has an unrestricted platform capacity of 230kg. It is a so-called parallel hybrid and equipped with an 18.6kW engine.

Abu Dhabi-based

of 1,800 tower cranes,

NFT for Tower Cranes

won the contract to

has completed the

supply the cranes in

supply and installation

December last year.

of 26 Potain tower

According to Ghady

TRIMbLE

cranes at the kuwait

El Hachem from the

TECHNOLOGy

International Airport’s

company’s sales

IN WORLD CUP

new $$4.3bn passenger

team in kuwait, this

STADIUMS

terminal project.

was based on “the

Eight of the 12

The cranes, which

impressive strength

stadiums hosting

are being used by

and reliability of the

the 2018 World

Turkish contractor

Potain cranes”.

Cup in Russia

Limak İnşaat, include

have been

six high-capacity

cranes will lift the

constructed using

Potain MD 1100 cranes,

heaviest material on

Tekla Structures

as well as 18 Potain

site including concrete

software from

MD 365 units and two

beams and columns,

construction

Potain MC 125 cranes.

while the two MC 125

software

NFT, which is one of

units will lift the lighter

heavyweight

the biggest tower crane

loads. The 18 MD 365

Trimble. The

owners worldwide with

cranes are ideal for the

company said

locations throughout

main steel structure

Tekla Structures

the Middle East, Asia,

and will also assist with

is an advanced

Europe, Africa and

concrete handling

Building

Australia, and a fleet

work,” he added.

“The six MD 1100

Information Modeling (BIM) tool, which allowed the designers, contractors and construction organisations behind the stadiums to turn in quality work.

MaMMoet adds Mini Crawlers Heavy liftin g an

d transport Mammoet specialist , known fo r its massive projects an lifting d cranes, h as now add capacity m ed new 4t ini crawler cranes to ex end of its fl pand the sm eet. The Du all tch-built H crawlers ar o efl on C10 min e telescopic i models mea 800mm in suring just width to fi t th rough nar doorways, row gaps an making th d em a suitab operate in le design to confined sp ac es .

Mammoet the new cr said anes are su itable for re and plants fineries where ther e are space constraints for conven tional cranes.

11

Bobcat to build backhoes in India

ONLINE TENDER SALE due to termination of projects in Angola

ASSETS HEEREMA PORTO AMBOIM LDA

TWIN SCREW HARBOR TUG BOAT “Yeunsoo Shipbuilding Co. LTD” (2007), overall length 33,80 m, width 9,40 m, draft 3,10 m, speed 13 knots, port of register in Panama, main engines: 2x “Niigata” 1800 HPO (750 RPM), with accommodation and mess for 8 persons, 10-persons inflatable life rafts, complete firefighting equipment, navigation with a.m.

Radar_GPS_Echo sounder;

Compact equipment specialist Doosan Bobcat has announced a new backhoe loader plant in India, marking its entry into one of the world’s three largest markets for the compact construction equipment industry.

The company, which is the market leader in the compact machinery segment in the Middle East and offers three models of backhoe loaders in the region, acquired the new Indian plant last month.

The facility sits on a total area 80,000sqm with a factory floor area of 15,000sqm. The production capacity is 8,000 units a year, said Bobcat.

Scott Park, Doosan Bobcat president and CEO, visited the new plant at the beginning of this month to check on its progress. Bobcat has entered the backhoe loader market to expand its emerging market portfolio with the aim of exploring mid- and long-term growth engines.

The company introduced its first ever backhoe loader

in 2016, choosing the Middle East as the launch market.

According to Gaby Rhayem, regional director, Middle East and North Africa, at Doosan Bobcat, including a backhoe loader in its product line-up in the region has enabled the company to offer a total compact equipment solution to customers in the region and helped Bobcat to cement its position as the market leader in the overall compact equipment segment of the Middle East market.

Bobcat has already become one of the top backhoe loader sellers in the Middle East within two years of launch and hopes to tap into the growth of the Indian market to replicate its Middle East success in the third largest s compact equipment market in the world after the US and China, with an estimated worth of $1.2bn, where backhoe loader sales account for more than 80%.

Since 2014, the Indian backhoe loader market has grown at an average annual rate of 9.7%.

3 MODERN CRAWLER TRACKED CRANES “LIEBHERR”

LR1400/2 (2015), running hours 3015 hour/ (Lattice boom heavy), main boom = 63m (heavy boom) / CWT 155mT and Car body 43mT/max. lifting cap. 168mT @ 9.2m radius (lifting cap. is governed by the main hook 250mT) and 2x LR1300 (2012/2009), running hours 6493 & 9115 hrs (Lattice boom heavy), main boom = 53m (Heavy boom), CWT 124mT and Car body 57mT, max. lifting cap. 144mT @ 10m radius (lifting cap. is governed by the main hook 160mT);

CLOSING: Thursday 19 JULY Viewing: by appointment only Location: Praia do Kissonde, Zona de Estocagem da Sonangol, Porto Amboim, Kwanza Sul (Angola) All documentation, CE certificates and specs are available on our website

www.TroostwijkAuctions.com

12

KIT SPOTTING JULY APRIL2018 2016

Terex Tower’s TAll TAsk A t the beginning of 2017, when Polish crane rental company Corleonis was tasked with erecting a roughly 150m-tall cooling tower for the largescale Bogatynia power plant in southwestern Poland on behalf of construction company Budimex, there was one question on everyone’s mind: Which crane could tackle the job in the most efficient way?

The new Terex CTT 332-16 flat top tower crane was chosen, as it fulfilled all the prerequisites for the demanding project. Its fast working speed and 16t lifting capacity ensured that construction would progress quickly, and its robust construction would enable it to work reliably in challenging job-site conditions.

“However, it was clear from the very beginning that even all the advantages behind the CTT 332-16 would not be enough to take care of the job with a standard crane configuration,” says Jacek Obrębski, commercial manager, Corleonis. “The crane had to be set up inside the cooling tower and would need to grow, as construction progressed, to a final hook height of 151.70m in three stages.”

The Terex Application Engineering team was able to solve this technical challenge quickly. They developed a cable structure that made it possible to anchor the crane tower to the cooling tower’s slab, enabling the CTT 332-16 to remain stable at all times. The first anchor was secured to the crane tower at a height of 62.40m and the second

at a height of 109.60m. This way, the Terex Cranes specialists were able to ensure that the CTT 332-16 flat top tower crane could efficiently perform all lifts with a jib length of 55m during every growth stage.

The support provided by Terex Cranes went even further, however. Regional sales manager Bartosz Irzyniec offered Corleonis – as a kind of full-service offering – commissioning support from a field technician from the Terex Cranes plant in Fontanafredda, Italy.

“Needless to say, it was the kind of offer that we wouldn’t have dreamed of passing up, especially given the fact that the crane model is still practically new for us. Basically put, the support provided by Terex gave us additional field experience,” says Obrębski.

Terex Cranes service manager Ivo Romanelli and field technician Mirco Manarin were responsible for this, and in March last year they not only assisted the Corleonis team with setting up the crane at the work-site, but also with commissioning, briefing, test lifts and fine-tuning.

During this initial stage, the crane was first erected to a height of 69m.

This was followed by 110.40m during the second construction stage and a final 151.70m during the third and final expansion stage in November.

“The CTT 332-16 crane proved to be an absolutely reliable machine, showing once more that Terex tower cranes are literally a true giant in the EMEAR region,” Romanelli summarises.

13 “The crane had to be set up inside the cooling tower and would need to grow, as construction progressed, to a final hook height of 151.70m in three stages… The CTT 332-16 proved to be an absolutely reliable machine, showing once more that Terex tower cranes are literally a true giant in the EMEAR region”

14

Chinese manufaCturers JULY 2018

On a cOmeback

Chinese manufaCturers are making the most of the market Conditions in the middle east to push their kit as not merely Cost-effeCtive solutions but quality produCts with full support

I

t may not be the best of times for Chinese manufacturers of construction equipment in the Middle East market, but it’s certainly not the worst of times.

While the region’s market is no longer in the heady days of 201516, the drop experienced from mid-2016 onwards has somewhat bottomed out and - spurred on by some must-deliver projects, such as Dubai’s Expo 2020 – there has also been a revival of sorts in the last couple of months of last year.

And the various Chinese manufacturers have reacted differently to the market conditions. While some, such as Zoomlion, have consolidated and synergised their business streams and offerings, others like Sany are trying to widen their reach and make inroads into new segments. Yet others, like LuiGong, are depending on research and development to provide the latest technological advancements, while the likes of SDLG are building on the excellent reach of their dealers to bring in customers.

At Zoomlion Gulf’s regional headquarters in Dubai’s Jebel Ali Free Zone, Wajih Eit, the newly appointed general manager, tells CMME that synergising the Chinese giant’s two big brands – Zoomlion and Italian concrete equipment specialist CIFA – is now the name of the game. Eit was previously the

head of CIFA for the Middle East and looked after the territory from the company’s base in Italy. But last year he was given charge of both CIFA and Zoomlion Gulf and tasked with consolidating the two brands together in the region, along with setting up a joint central support structure for both.

While CIFA’s concrete equipment is now fully supported from the joint ZoomlionCIFA base in Jafza, Dubai, the new synergy between the brands has also benefitted Zoomlion, whose crane products have been its best-sellers in the region.

“Talking about the mobile cranes and tower cranes, Kuwait is doing very well at the moment. And the UAE continues to be one of the best countries, while Egypt is also pretty buoyant,” says Eit. The rough terrain crane (RTC) underpins Zoomlion’s business in the region, he adds, with Saudi Arabia being one of the most important markets. “We are doing very well in Saudi and recently closed a big order for RTCs with a top global oil & gas company.

We are a market leader in the RTC segment.”

The UAE, Kuwait and Egypt are also quite important markets for Zoomlion where mobile and tower cranes are concerned. “In the tower cranes today, we are one of the top suppliers and are going after the landmark projects. In 2017 we supplied one of the biggest tower cranes ever from China for the new Kuwait airport terminal project. It’s a 150t Zoomlion

15 Rough terrain cranes are leading the sales for Zoomlion in the Middle East, and the company plans to capitalise on that to push its earthmoving and concrete products.

“The most important thing is the technical support, the spare parts, the local network of dealers helping you. Customers will try Chinese products and if they like the quality, performance and support, they are so going to shift”

tower crane of which we supplied six units.

“Among other recent successes, in the UAE we just sold five luffing jib tower cranes to China State Construction (CSCEC), and five more in Saudi to Al-Arab contractors for a project in Jeddah,” says Eit. Cranes have become an area of huge importance for Zoomlion in the Middle East, as well as in other markets, especially in the 100t and below truck cranes.

“But when we go above, we are the first and only supplier to have supplied truck cranes over 150t to Kuwait last year. The most important thing is the technical support, the spare parts, the local network of dealers helping you.

Customers will try Chinese products and if they like the quality, performance and support, they are so going to shift.”

Pursuing this philosophy, Zoomlion has already stocked up on millions of dollars’ worth of parts and spares at its Jebel Ali facility in Dubai, Eit reveals. The parts cover the full range of Zoomlion equipment, from cranes to earthmoving and concrete machinery, including CIFA, he adds.

Eit feels there is still room for improvement in Zoomlion’s earthmoving offerings, which has not been in focus because the brand’s core business in this region was in concrete and cranes. “But we had an internal review last year and decided to focus afresh on this segment as well as on piling, where we have very good products. So, in the next two years we will see a lot of investments from Zoomlion in these sectors to increase our market share, as we did in the cranes.”

Market perception For most Chinese manufacturers, there is another obstacle to overcome – and that is market perception; an association with low price and quality compared to the big Western and Japanese brands. But each brand has its own strategies to combat this perception.

Ahmed Adel, business development manager at LiuGong, says: “The market sometimes perceives Chinese machinery negatively, including in the Middle East. To break these prejudices, LiuGong’s strategy is to constantly invest in R&D and build an international network, as well as raise consumer awareness on our quality.”

LiuGong is actively expanding its dealer footprint in the region and aligning the vision of its partners to its mantra of providing prompt and quality response to customers, whether new or existing, Adel says.

“Also, our R&D has made several breakthroughs and we have upgraded our traditional manufacturing process by integrating intelligent manufacturing technologies. The results are showing with

16

Chinese manufaCturers JULY 2018

Oman explOits

Joint suCCess for sdlg and genserv In only five years since

provide quality brands and

can rectify issues with

General Engineering

good parts and service,

the machines. Oman

Services (Genserv)

and so they said, ‘If it’s

is 310,000sqkm with a

introduced SDLG to

coming from Genserv, then

population of 4.4 million.

Oman’s construction

it must be reliable’. Once

Our goal at Genserv is

equipment market, the

the machines were out

to be accessible to all

Muscat-based company

in the field, their benefits

customers within 24 hours.”

has seen the Chinese brand

spoke for themselves.”

become one of the most

Genserv has been in

“We recently sold a fleet of SDLG graders, rollers

business for 34 years

and wheel loaders to an

and is well trusted in

aggregate and quarry

introduce a new brand

the region, and Rashed

customer in the region.

into an established market,

explains: “Customers want

They had previously only

but we used our name and

to have confidence in

used premium machines

reputation to promote

the accessibility of spare

but decided to make the

trust in SDLG,” says Ahmed

parts, the availability of

switch. It worked out really

Rashed, GM, Genserv. “Our

the service people, and

well, and they are very

customers expect us to

in the speed at which we

satisfied with the quality.”

requested in the field.

“It was a challenge to

our wheel loaders hitting the cumulative sales milestone of 350,000 units this year, and our excavator sales rising 150% year-on-year.”

At Sany, meanwhile, a partnership with UAE powerhouse United Motors and Heavy Equipment has made a huge difference in the way it is seen by the market. A senior functionary from United says: “After our customers see and experience our concreting equipment, crawler cranes, excavators and wheel loaders, they start appreciating the quality of Sany products. Our machines are getting similar results at less cost compared to the more glamorous brands. ‘Made in

Chinese giant LiuGong is investing heavily in research and development to produce topnotch products and dispel perceptions about Chinese brands being low on quality.

China’ is not a deterrent for quality as even the largest global brands are manufacturing their products there. Once our customers start using Sany equipment they acknowledge that it offers far more value for their money.

Products also need to provide customised features to survive in this market, and we are glad that Sany offers them.”

Speaking of customisation brings us to what the manufacturers do to make their products fit for this region, which has some of the most demanding conditions one can encounter globally. LiuGong’s Adel explains: “In the Middle East, along with the high temperature,

dust and demanding terrain, there is also low fuel quality. LiuGong provides extra-cooling capacity and ultra-high-efficiency filters, and also focuses on strategic components.

Our casting department is the foundation of LiuGong components and for 60 years we have worked closely with leading names such as ZF, Cummins and Kawasaki. This has enabled us to provide high-quality solutions for transmissions, hydraulic systems and foundry components.”

Another big Chinese brand, SDLG, which is part of the Volvo Group, has leveraged its parent’s know-how and global market knowledge to notch up successes in the Middle East recently, such as supplying large orders of motor graders for infrastructure and maintenance work in Saudi Arabia and selling several wheel loaders to quarries in Oman.

Shahir El Essawy, project director, Hub South (Middle East and Africa) at SDLG, says: “The Middle East/GCC market requires highperforming and reliable machines, with good serviceability and fuel efficiency. We believe our machines are well-built and prepared to cater for all these needs.

“Our F-series wheel loaders introduced in the region have high breakout forces and a new bucket design for improved productivity and ease of operation. They have been designed to ensure service and maintenance can be handled easily, with excellent accessibility throughout the machine. We are also supplying our F-series backhoe loaders our latest range of backhoes with a modern, reliable and high-performing design - as well as expanding our motor grader range.

“Of course, there is a cost difference

17 between Western and Chinese brands; however, in SDLG’s case, I wouldn’t say it’s low quality. From design to production, we focus on reliability and ease of service of our machines. We aim to always provide our customer with the best products and aftersales support among the Chinese brands.”

The mention of aftersales support brings up a vital point. However well-built, a machine is just as cost-effective as the constant uptime it can provide. For this, SDLG relies on its extensive dealer network in the region, which it mainly shares with Volvo CE. El Essawy points out that SDLG’s dealer network in the region is characterised by competent and fully-trained personnel backed up by full support from the manufacturer.

For Sany, the association with United is the key to its after-sales backup, with stringent norms that its dealers need to meet. “With the introduction of CRM systems, the support level from Sany has improved further. Moreover, at United Motors our service teams are undergoing continuous training on the entire equipment range under Sany engineers’ supervision,” says the United senior official.

This approach has led to many successes.

“Recently, we’ve delivered 22 units of various concreting equipment to M/s Golden Ready Mix and 14 concrete pumps to M/s Oryx Mix. We also sold over 10 crawler cranes in 2018 in the UAE, apart from 18 excavators.

Contractors Saif Bin Darwish placed an order for 23 excavators only after successfully testing the first lot of eight units they bought in 2016.

All our customers are quite content with our machines and support arrangements.”

LuiGong too has tasted success with its

products thanks in no small measure to its service deals. “Our annual service plan includes periodic technical training of dealer personnel. Moreover, our teams frequently visit customers regardless of whether there is an issue. And we regularly evaluate dealers’ performances,” explains Ahmed Adel.

The list of LiuGong customers in the region is a prestigious one, comprising Aramco, Arab Contractors, Petrojet, Orascom, Habtoor, Amer Group and Lafarge, Adel says. “Last year LiuGong launched 26 new products. Our H-Series wheel loader and E-Series hydraulic excavator are popular in many countries in the

With a wide range of products, and with its association with quality dealers, such as United Motors in Dubai, Sany has found recent success in the region’s market with several sales.

region, and our revolutionary vertical lift wheel loader, VL80A, is listed in the Chinese National Innovation List as a major achievement.”

With the Middle East a potentially big market, the Chinese are bringing in more equipment in the future. Sany will introduce rigid dump trucks, vibratory compactors, pavers and also port equipment. LiuGong is bullish on its CLG856 and CLG856H wheel loaders built using joint-venture technology with Cummins, ZF and Kawasaki. In the next couple of years, it looks like the Chinese dragon will truly spread its wings across the Middle Eastern machinery landscape.

Bullish On the dOzer

shantui’s new full hydrostatiC range Chinese construction equipment

first model – the SD10YE – in

heavyweight Shantui has

2009. Machines in the new

launched a new series of

range launched in Paris can

hydrostatic bulldozers that

easily adapt to various working

covers the full range of the

conditions, he added, such as

pushers and is suitable for

public works construction,

various construction and

building golf courses and

mining applications.

even heavy load mining.

Officially unveiling the three

Shantui has been selling

series and six grades of the full

hydrostatic products in more

range of hydrostatic bulldozers

than 20 countries and regions

at this year’s Intermat in Paris,

globally including Europe, USA,

Liu Kun, Shantui’s business

the Middle East and India. Apart

director for Europe, said that

from dozers, the company, which

while the company began

is a subsidiary of the Shandong

research and development

Heavy Industry Group, also

on hydrostatic bulldozers

manufactures excavators, wheel

in 2008, it produced its

loaders and road machinery.

18

INTERVIEW JULY 2018

Speed of AcceSS

AWP rentAl giAnt rAPid Access is using its extensive fleet And Presence in the region to extend its reAch into neW Projects And technologies, mArketing mAnAger joe keely tells CMME, As he demonstrAtes the lAtest virtuAl reAlity oPerAtor testing tool

T

he powered access sector is one of the most vital in the construction and equipment landscape globally and also in the Middle East. Among the most prominent rental companies in the sector is Rapid Access, part of the Loxam Group, the third largest rental company in the world. Covering the whole of the GCC, Rapid Access has a presence in every country in the region.

Speaking about the company’s operations, Joe Keely, marketing manager, Middle East, tells CMME that Rapid Access has three depots in Saudi Arabia and one each in Bahrain, Kuwait, Oman and the UAE. “We are the largest rental specialist in the GCC. Rapid Access provides booms, scissors and other powered access equipment. We have around 4,000 machines in the GCC and we’ve been here since 1996.

“In terms of major projects, we’re working on the Dubai Expo 2020 site with Al Futtaim Carillion. We also supply a large number of machines to Emirates airline for maintenance.

Contractor Nasser Al Hajri is a big customer of ours in Saudi Arabia, especially for the Jizan petrochemicals complex. We also work with the Kuwaiti oil company. Our machines can be found in the Riyadh Metro project and some have been rented by contractors working

on the Dubai Metro’s Line 2020 extension.

Another big project where Rapid Access is supplying machines is the mid-field terminal at Abu Dhabi airport with Chadwicks. Basically, any large capital project in the region will see our involvement in some way or the other.”

Speaking of projects leads us to the new practices in the construction sector – of moving away from scaffolding and using more Mobile Elevating Work Platforms (MEWP). “This is a global practice now and of course the Middle East is adopting it too. The earlier Metro lines in Dubai saw heavier use scaffolding but for the new line it’s MEWPs replacing them wherever possible,” Keely explains.

“MEWPs are safer, more compact and mobile. They don’t need to be installed at a site for the duration of the project. You get a better look at your building when it is not covered by the scaffolding and MEWPs are also easier for working at heights. They are safer for many reasons, such as less wind loading, and you can bring the people down if there’s an issue rather than having them climb down the scaffolding. You’re also able to take more tools and materials up high with you use a platform.”

Rapid Access has a diverse fleet in terms of manufacturers, Keely says. “We work with all AWP makers, even though the brand colour of our machines is blue. That makes it look like we’re a Genie fleet, but we do have significant numbers of JLG. Among the OEMs, Genie and JLG are our biggest partners, but

19 AWP rental giant Rapid Access has three depots in Saudi Arabia and one each in Kuwait, Bahrain, Oman and the UAE (below), where it takes care of maintenance and service.

“We have three depots in Saudi Arabia and one each in Bahrain, Kuwait, Oman and the UAE. We are the largest rental specialist in the GCC… Basically, any large capital project in the region will see our involvement in some way or the other”

20

INTERVIEW JULY 2018

ImmERsIVE TRaININg

stimulAting simulAtion Rapid Access’ latest offering is

machine. Or if you know how

a virtual reality (VR) simulator,

to operate a machine, those

that enables people to build up

skills can be used here as well.

competency and confidence

“We are selling this VR

in operating booms and

simulator. We are the only

scissor lifts. The simulator

distributors for it in the

consists of several devices

Middle East and this is the

forming an integrated system.

first machine of its kind in the

Controlled by a computer, it

region. We are also looking

has the basket and controls of

to diversify our package

an AWP machine in which the

effectively to the customer.

operator takes up his position

So, for customers who hire

and wears a VR headset with

from us, or customers who

visual and audio channels,

want to hire this specifically,

through which he is immersed

it is part of our rental fleet

into VR scenarios programmed

and is something that we

into the computer. Each

will rent out for customer

scenario consists of virtual

demonstrations.”

tasks for the operator to

Keely adds that companies

perform that will test his skill

and projects that have large

in operating the machine.

numbers of people operating

The controls respond

AWP equipment will use

just like a normal machine

a product like this to test

and the basket generates

operator competency. “They

motion depending on the

are required to have an IPAF

way the operator is using the

licence, which certifies that

equipment in his VR world,

they’ve been trained, but it

giving him the impression of

doesn’t necessarily show

operating an actual machine.

they are competent in the

There are several levels of

use of the machine. This

tasks, each progressively

simulator is a very quick and

more complex, and he is

simple way of testing the

marked on his performance

competence of the operator.”

at each level according to the skill displayed.

So far, Rapid Access staff have been accompanying

“It’s a fully immersive,

the simulator for demos, but

virtual reality world, and it’s

that won’t always be the case,

a simulator that rocks and

Keely explains. “It is a very

moves depending on your

easy thing to become familiar

operation of the machine.

with and set up – it takes only

The benefit is that you’re able

about 15 minutes for setting

to train and understand how

up – and it doesn’t need much

the equipment works in a

space. So, it’s something we

completely risk-free scenario.

could go in and install, and

So you can operate an AWP

then the customer company

machine using this simulator

can operate it on their own.

knowing you’re not going to

“Once set up and in place,

do any damage to machines,

it’s only a case of turning the

people or the site you’re

laptop on and off. It’s a very

working on,” says Joe Keely.

simple piece of kit. It looks

“It’s got standard industry

complicated and I’m sure it’s

controls, which operate in a

complicated to design and

manner identical to real-life

build, but the ease of use is

machines. If you can build up

a boon to companies who

knowledge on how to operate

would like to test the skill

here, you would be able to

levels of their operators and

transfer those skills onto a real

upskill them,” explains Keely.

21 we also use Haulotte and Niftlift booms and Skyjack scissors. We also have scissor lifts from specialist companies such as Omme. But 60% of our fleet is Genie, more because our parent group, Loxam, has a very close relationship with Genie globally.”

The Middle East AWP sector differs from others by preferring large boom lifts, says Keely, and Rapid Access is prepared for that here. “The European market its probably 60% scissor liftbased and the Middle East market is probably 60% boom-based. There’s a lot more work done with our equipment here at extreme heights and we have significantly more big booms in this region. This is partly due to some very tall construction here, and also because of the oil & gas projects,” Keely explains, adding that the uptake of scissor lifts is increasing in the region and “our fleet mix has changed in the past couple of years, with scissors now comprising double-digit percentage points”.

But it’s still the booms that dominate.

Diesel is also the Middle East’s clear power choice, not electric or hybrids, Keely notes.

“Of course, the scissor lifts are electric; for almost all other models its diesel. I don’t think we’re going to move away from that here soon. Obviously, electric is a better option for indoor facilities management, but most FM companies here still use a lot of scaffolding and ladders. Our business is mainly in external construction, not internal fit-outs,” he says.

Discussing Rapid Access’ business brings us to one of the most important aspects of its service proposition – operator training.

“We have an option of providing operators when we rent out our equipment, but typically

With a fleet of more than 4,000 machines across the GCC, Rapid Access can provide every kind of AWP machine available on the market, from tall booms to scissors and more.

people use their own. It’s more economical for a contractor to have his workers trained and operating the machines he rents than to hire one along with the machine,” Keely reveals.

“So, we encourage people to do their training with us and we sell a lot of training courses. We are an authorised training partner of the International Powered Access Federation (IPAF) and we’re also the world’s largest provider of MEWP training. Training our customers’ operators also means that they use the machines in a far safer and reliable way.”

3D PRINTINg

incorPorAting technology Rapid Access is among

facility where we print a

then get printed using our

the global pioneers of 3D

few parts. It takes typically

3D printing equipment

printing of spare parts

around three hours to

and we’re also looking at

in the powered access

print the sort of parts we

bringing in professional

industry, says marketing

are printing as of now, but

3D scanning technology.

manager Joe Keely. The

it saves money and also

These are huge scanners,

company has started in a

improves parts availability,

which will enable us

small way but has plans

thereby improving overall

to expand the range of

to expand its 3D printing

efficiency,” says Keely.

parts that we can print.

initiative further and soon

Rapid Access started

“Even though we have

print not just small parts

3D printing of parts in

started only with plastic,

but also major ones.

their Dubai facility around

the technology available

four months ago and only

includes printing in

parts are printed and the

three or four different

carbon fibre or even

printing is restricted to

parts are 3D printed at the

titanium, which we will

non-safety related parts.

moment, but it’s looking

incorporate soon, as we

We have a 3D printer at our

to expand that. “We are

are looking to expand our

parts and spares section

working on designing our

3D printing capabilities

in Rapid Access’ Dubai

own parts, which we can

quite quickly,” Keely says.

“So far, only plastic

I’ts not mandatory for every customer to take the company’s training, but it’s often site and contract specific. On some jobs and companies Rapid Access provides the training with the machines. “For example, Aramco requires all its operators to be IPAF certified and so do the Dubai Expo 2020 organisers for all operators working on their sites, so we do the training for them,” Keely says.

The biggest recent news at Rapid Access is that it’s extending its training options with a new virtual reality simulator, (see box) to test and develop better operator competency.

“It’s like driving a car: with time you’re likely to get some bad habits. Our new VR simulator enables you to return to a better standard of work. It’s like a refresher course, enforcing better practice in a cheaper, controlled environment, and it reminds you of certain things that you may have forgotten. It allows large contractors to prove the competency levels of their operators,” Keely elaborates.

Looking into the future he feels the focus on health and safety will increase, and people will consider AWP equipment earlier in the building process rather than later, as now.

Also, the use of scissor lifts, electric, hybrid and bi-fuel machines will increase.

“Both these factors will lead to our product line becoming more prominent at job-sites,” Keely says. “And, led by the large companies, the powered access sector in the region will move towards greater emphasis on training and professional development. So, we anticipate a lot more work for our training division going ahead.”

Powered Access rePort Powered Access Report – Gaining Access The powered access sector is a vitally important part of the construction landscape. Useful in both construction and maintenance, powered access products are not only used for façade and cladding work, and for working at heights, but also remain behind for maintenance purposes once a project is complete. and with recent advancements in the sector, powered access products now offer ever greater reach and height, along with fuel and power options for a variety of usage conditions.

Manufacturers, Dealers, Services and Trends CMME takes a look at the powered access sector in a report that will cover the major manufacturers, dealers, rental companies and service providers, as well as the machines, projects, training, safety and trends in the sector.

Contact us Now The Powered access report will reach over 45,000 industry professionals across the Mena region via print and digital issues of Construction Machinery Middle east august 2018 issue.

Tom Bromley adverTising tom.bromley@cpitrademedia.com +971 56 834 2600

anirban Bagchi ediTOriaL anirban.bagchi@cpimediagroup.com +971 50 945 6963

23

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

KNOW

28

TOP 10: ckle TiPs TO Ta The heaT

24_NeW Releases The latest releases from the world of construction machinery.

p llow to kee Steps to fo achines men and m mmer. fit in the su

30_build iT like bObcaT CMME takes a behind-the-scenes look at the stringent quality controls at Bobcat’s plant in the Czech Republic.

36_PumPed uP PeRfORmaNce Truck-mounted concrete pump makers up the ante in boom length and strength, component quality and service.

40_Jcb’s fORmula Formula 1’s Williams and JCB forge a winning partnership.

24

NEW RELEASES JULY 2018

new ManitowoC Crane diagnostiC app Why get it? incrEasE uptimE with quick intErprEtation of fault codEs

JCB introduCes new 20t digger Why get it?

EnhancEd opErator comfort, improvEd hydraulics JCB has developed advanced new 220X crawler excavators, the first models in the next generation of JCB tracked machines for the global construction market. Over a four-year development period, JCB has employed a programme of intensive component and product testing, to achieve increased levels of build quality and reliability for customers.

The new machines feature: 15% larger cabs with integral ROPS structure, offering reduced noise levels; 200mm wider upper structure delivering improved packaging; central main boom mounting for increased digging accuracy and durability; intuitive, ergonomically-designed cab with simple user interface; stronger side doors for greater strength and increased protection.

JCB’s chief innovation and growth officer, Tim Burnhope, said: “With the next generation 220X, JCB has moved to a totally new level of product development and machine assembly, that will benefit all of our excavator customers in the field.

“Every detail of these excavators has been examined and perfected, to provide maximum durability and reliability in operation. But more than that, we have made it easier for the operator and for the service technician, reducing downtime for the customer and boosting profitability. The 220X heralds the arrival of a new generation of JCB excavators, that will provide many years of faithful service across the world.”

The cab incorporates the ROPS frame within the structure and has flat glazing

all round. The 220X boasts a low 68dB(A) noise level inside the operator cab, down from 73dB(A) on the previous generation.

Inside the cab, an all-new command pod brings together all switches and controls into a single seat-mounted unit. A seven-inch tilt-adjustable monitor has been provided with intuitive menus and functionality. The monitor is accessed through an automotivestyle rotary controller. By combining the benefits of the screen and the command pod, which has a button for every regularly used function, tests have shown that an operator can carry out regular operations faster, said JCB. The machines can be supplied factory-prepared for GPS excavation guidance, tilt-rotator and autolube.

The new 20t class excavators have a new appearance, which will be carried throughout the range. The excavators have an upper structure that is now 2.7m wide, 200mm broader than their predecessors.

The additional space has allowed JCB’s designers to mount the main boom in the centre of the machine, rather than at an offset. This reduces stress on the slew bearing and provides increased accuracy for the operator when trenching.

The diameter of the main hydraulic hose to and from the main hydraulic valve has increased in diameter from 19 to 25mm, giving greater flow without increasing the speed of the oil.

SPECIFICATIONS

JcB 220X crawlEr EXcavator Operating weight: 20t Main hydraulic hose diameter: 25mm Upper structure: 200mm wider Cab noise level: 68dB(A)

Manitowoc has released a free diagnostic mobile app to increase crane uptime for customers. The new smartphone app is available for iOS and Android devices, and will help crane operators interpret diagnostic codes that are generated by on-board control systems.

The app aims to increase crane uptime by enabling customers to diagnose technical issues without third-party assistance, leading to faster repairs and maintenance. The app will enable users to understand the numeric diagnostic codes that are generated by their on-board control systems. Manitowoc claims to be the first manufacturer in the crane industry to release an app of this kind.

In the past, when cranes had technical issues, Manitowoc customers had no way to interpret the diagnostic codes that would appear on the main display of the crane’s cab. Specialised technicians would have to be called to the job site with proprietary equipment, and any time spent waiting affected the project schedule. The company says that now, with this freely available smartphone app that instantly tells users what codes mean, crane owners can begin working on solutions immediately, boosting their uptime.

25

Cat refines three new artiCulated truCks Why get it? advancEs in powErtrain, control, safEty and opErator convEniEncE Three new Cat articulated trucks — 730, 730 EJ (Ejector), and 735 — have been extensively redesigned, enhancing the field-proven features and performance of their C-Series predecessors (730C2, 730C2 EJ, and 735C) with new operator stations, including innovative new controls, transmission-protection features, new hoist-assist system, advanced traction control system, new stability-assist system, and a fuel saving ECO operating mode.

In addition, the design of the 730 and 730 EJ is enhanced with automatic retarder control and a hill-start feature. The 735 retains these features from its C-Series predecessor and further incorporates design refinements that include a new Cat C13 ACERT engine, Cat CX31 transmission (also on the 730 and 730 EJ) and structural and dimensional modifications that reduce empty weight by 22%, while retaining the productivity of the outgoing 735C. These features combine for an up to 19% gain in fuel efficiency.

The cab’s new external “spinal-ROPS”

design incorporates a rear-quarter glass that eliminates a structural pillar in the C-Series design, for enhanced rear visibility. Also, a new “wake-up” feature initiates the machine’s displays when the door is opened. The door is of a lighter, stronger design with a shutassist feature for improved sealing against dust infiltration. The overall cab design results in lower inside sound levels at 72dB(A), a 7dB(A) reduction compared to previous models.

Optional new infrared glass reduces solar heating inside the cab, and left- and righthand sliding windows increase ventilation and facilitate communication with workers and the loading-vehicle operator. A new, automatic climate-control (HVAC) system positions more vents above and behind the operator for increased heating and cooling efficiency.

A new heated/cooled seat is designed to give operators increased adjustments that allow “dialing in” personal-comfort settings; also, the passenger seat now uses a flip up/ down design and added cushioning.

For added safety, a new lighting system, controlled via a ground-level switch, illuminates the cab’s entry steps and hitch area. Optional integrated payload lights provide an external

indication of payload levels for the loader operator. Optional long range, LED work lights improve visibility at night or in situations of lower visibility. New cab-mounted mirrors, including a front-visibility mirror, enhance all-around visibility for the operator. Exterior cab features include an improved flexible lower fender and a low-profile exhaust stack that need not be removed for transport.

Further enhancing safe operation is the Cat Advanced Automatic Traction Control system, which features refined technology for proactively applying differential locks to avoid wheel spin. Also, a “terrain-based” throttlesmoothing system prevents acceleration surges when traveling over extremely rough terrain that makes keeping a steady pressure on the throttle pedal difficult.

SPECIFICATIONS

cat 730, 730 EJ & 735 Net power: 367hp & 428hp Rated payload: 30.8t, 31t & 35.2t Number of axles: 3 Drive configuration: 6-wheel

26

NEW RELEASES JULY 2018

hitaChi deButs new wheeled exCavator Why get it?

Eco-friEndly high-powEr EnginE without diEsEl particualE filtEr

Cat expands work tool line-up Why get it? multi-procEssor implEmEnts for a variEty of dEmolition tasks Caterpillar Work Tools has expanded its range of excavator attachments with three new multi-processor models — MP332, MP345 and, MP365 — which build on the company’s demolition-technology experience with new features aimed specifically at users requiring large, flexible, purpose-built tools that can handle virtually any demolition task. The new models join the MP318 and MP324 in the Cat multi-processor range.

The design of the new multi-processors allows pairing a basic housing with any of up to six jaw sets, increasing jobsite versatility; the design also boosts productivity with patent-pending features, such as a new jaw locking system and the Speed Booster valve.

The net result is optimum performance, coupled with low owning and operating costs.

The new MP300 Series models are compact and designed with a high power to weight ratio, delivering exceptionally strong cutting and crushing power, while reducing stress on the carrier. Also, the housings used for the new tools incorporate a heavy-duty rotator that provides 360-degree movement for positioning the multi-processor at an optimum angle for any demolition situation.

In operation, when the jaws meet resistance, the integral hydraulic booster valve automatically activates. The Speed-Booster system combines a “speed” and “booster” valve and can therefore use a smaller cylinder diameter (compared with previous models), which nearly halves cycle time for jaw opening and closing. In addition, depending on the jaw set used, closing force is up to 19% higher, compared with previous-series models.

In a sign of the advancements that environmentally friendly technology is making in the world of construction equipment, Hitachi has introduced a new wheeled excavator that not only meets the highest emission norms for machinery in the world at the moment but also does it without the need for the cumbersome diesel particulate filter.

While it’s not aimed at the Middle East, or similar regions where emission norms still lag behind compared to the developed markets, the machine is a pointer towards the times to come when the stricter emission standards are eventually extended to the less- and non-regulated markets worldwide.

The ZX190W-6 wheeled excavator has a 172hp Tier 4-F Isuzu engine that does not need a diesel particulate filter (DPF).

The model’s operating weight is 20.5t. Its HIOS IV hydraulic system contributes to fuel efficiency by delivering on-demand performance and the right amount of pump flow when metering pilot controls. Additionally, power and performance is balanced

with three work modes. Economy (ECO) maximises fuel efficiency while delivering an enhanced level of productivity. Power (PWR) delivers a balance of power and speed, plus fuel economy for normal operation. High Productivity (H/P) delivers more power and faster hydraulic response.

Wheeled excavators are catching on in the Middle East, with maintenance and construction works in the increasingly built-up urban environment requiring machines that can be easily transported on roads and paved areas without damaging the surface. Hitachi’s ZX series is one of the favourites in the region in this regard.

The ZX190W-6 also shares this trait and can be roaded at speeds of up to 35km/h.

Maintenance features include at-aglance gauges and grouped service points with easy access to the washer tank, air cleaner, DEF tank and battery disconnect switch. A redesigned counterweight with LED lights and rearview camera enhance job site visibility.

The ZX190W-6 is protected by a heavy-duty undercarriage and durable D-channel side frames. Added strength comes from welded bulkheads within the boom that resist torsional stress, tungsten-carbide thermal-coated arm surfaces, and oil-impregnated bushings.

SPECIFICATIONS

hitachi ZX190w-6 whEElEd EXcavator Operating weight: 20.5t Travel speed: 35km/h Rated engine power: 172hp Bucket capacity: 0.51-1.20 cubic metres

TOWER

CRANES SPECIALISTS Bothani ENG Cranes

Tel. 04 327 1141  P.O Box 393443, Dubai, UAE  info@bothani.com www.bothani-eng.com

28

TOP TEN JULY 2018

01 air CONdiTiONiNg Machines with air-conditioned cabs are a must in the summer heat in the Middle East, not a luxury.

Use equipment with cabs that are air-conditioned and laid out for ergonomic comfort, to maximise operator productivity. Also ensure the AC systems are properly serviced before summer starts.

02 ChOOsE aPPrOPriaTE kiT The Middle East summer is among the harshest working environments in the world – and not all manufacturers take this into account while producing their models for the world market. Stick to kit from the tried and tested top brands which customise their machines for the region’s conditions and are popular in the market.

: n e T p To g n i l k c a T r o f s Tip T a e h r e m m u s The es and n i h c a m er w to keep eath ollo f w o t t o s h p e e t h s rder in t o d o o g men in

03

ChECk COOlaNTs aNd fluids Top up your machines with the recommended grade of coolant.

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

Tyre check

e air tures rise, th As tempera s and res expand inside the ty ure on the walls. press exerts more ted tyre can burst fla in An overng serious ssure, causi re p e th m o wears fr Rubber also accidents. onitor mmer, so m faster in su en. Also re more oft tyre pressu ore condition m check tyre e g and chan frequently, if worn out.

04

29

05

06

sTriCT maiNTENaNCE The stress of working under the hot conditions makes machines more prone to failure during the summer months than at any other time. To prevent this, ensure your machines are looked after and take extra care to stick to proper maintenance schedules.

usE maChiNEs OvEr mEN Machines can withstand heat much better than workers and still be efficient. While it’s usually more cost-effective to employ workers in our region, make an exception for the summer months. Wherever possible, replace men with machines or consider new attachment options, machine control devices or other labour-saving tactics.

Break ofTensearing

the Working in gion is o t a f the re nce. summer he e ing exp rie p p a -s y rg e r pace an en ad to slowe le n a c ss e istakes Tiredn eness to m n ro p d n a of work chines in en and ma have that put m ra re ope tors su e k a M r. e in dange aks and tak frequent bre re o st ids to re enough flu . y their energ

09 08

mEETiNg bEfOrE shifT Reinforcing the message of being aware of the effects of the heat and heat exhaustion can keep your staff more prepared to deal with the conditions.

This is best done in a meeting before every shift, during which safety plans are outlined and the team is reminded of site conditions and potential hazards.

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

10

07

CarEful sTOragE Any equipment not in use during the summer must be stored away correctly indoors or in a shaded area, covered and protected from the elements. Leaving it out in the yard will lead to potentially disastrous sand accumulation in critical components, such as hydraulics and fluids.

30

COVER STORY JULY 2018

Bobcat’s EMEA manufacturing facility at Dobris, near the Czech capital of Prague, produces the skid-steer loaders popular in the Middle East market, such as the S450.

“It’s fast, precise and repeatable, with the aim to give us repeatable quality, and this requires the exactness that we employ in our processes… We work with the ‘just-in-time’ manufacturing paradigm, which keeps the operation very lean and economical, keeping costs down for our customers”

31

Build it like BoBcat

CMME goes behind the scenes at the plant where the Middle east’s favourite coMpacts are Made and coMes away iMpressed by the dedication to quality. anirban bagchi reports

W

hat’s common between a shopping mall and a Bobcat factory? Both have supermarkets and Bento boxes.

But it’s not your everyday groceries that the ‘supermarket’ at the Bobcat factory in Dobris just outside the Czech capital Prague stocks. Neither is the Bento box at the factory full of Japanese treats. Instead, the shelves of this supermarket are stacked with parts and components that go into making the skid-steer loaders and compact tracked loaders that are so ubiquitous at job-sites in the Middle East, along with mini excavators. And the Bento boxes are trays with separate compartments for parts used for manufacturing the machines in the sprawling 22,000sqm facility, which itself is part of this bigger Bobcat campus around 20km outside Prague. Along with the factory, the campus – Bobcat’s EMEA hub - is made up of its Innovation Centre and training centre.

Bobcat compact loaders and excavators have been manufactured at Dobris since 2007 and today the plant produces over 80% of its machines for the EMEA market. The plant has a workforce of over 500 and comprises state-of-the-art manufacturing equipment, including mobile welding lines, hi-tech paint shop, laser cutting centres and three assembly lines. Taking CMME on a tour of the plant, Vincent Frank, plant manager, Doosan Bobcat EMEA, points out certain salient features of the facility: “We work with the concept of islands in this factory. All the different parts of the loaders and excavators produced here are built separately in these island sub-assemblies before coming together on the final assembly lines. This gives us flexibility and

32

COVER STORY JULY 2018

modularity, and also enables more attention to detail with stricter quality control.”

Quality control is an important part of operations at the facility, with the entire team and all processes dedicated to achieving the highest standards possible - and continuously improving and refining them, once achieved.

Freddy Remory, product trainer, EMEA, explains that from the time the sheet metal arrives at the factory until a completely built machine rolls off the final assembly line, there are not only several quality check points that it needs to clear, but also each station and process in the making of a final product is geared towards producing the best results.

“All products begin with the steel sheet metal. When the steel comes in, it goes through the first step of quality control, receiving a thorough check for quantity, thickness and quality of the surface,” says Remory. “If everything is ok only then are the sheets released for production.”

When the steel is approved and delivered to the factory floor, it is piled one on top of another in what Remory calls towers. “We work with the four towers. Every tower has its own robot that picks up the steel and feeds it to a laser cutter. The cutting is done with precision with a high-tech, computer guided and automated laser cutter,” he says.

“Our laser cutters are extremely advanced pieces of equipment. Their advantage is that you have a very smooth and precise cut. The precision varies only about one-tenth of a millimetre. With the laser cutters that we have, we can cut through steel of 18mm, but most of the steel that we use is on average 5-6mm, with the minimum being around 2mm and the maximum around 12mm in thickness.

This is the most common sizes that we use both for loaders and excavators.

“It’s fast, precise and repeatable, with the aim to give us repeatable quality, and this requires the exactness that we employ in our processes. Another basic concept is that we cut what we need tomorrow, or the day after. You will see that there is virtually no excess stock. We work with the ‘just-in-time’ manufacturing paradigm, which keeps the operation very lean and economical, keeping costs down for our customers.”

After being precision cut the components receive the next treatment, which is bending.

“We have presses in various capacities. Starting from the small 50t they go all the way up to 320t. The bending and pressing process is also completely automated, so force and speed is calculated by a computer. This again gives us repeatability and so consistently high quality in the manufacturing process, leading to an equally quality product. The only thing the operator does is to feed the piece to

Rigorous testing and strict quality controls are integral to the production process at Bobcat’s Dobris facility to churn out robust machines that dominate the Middle East market.

BOBCaT S450

the new Middle east chaMpion The S450 also features a

The S130 used to be Bobcat’s

and 9.2mph in high range

– and indeed, the market’s –

when equipped with optional

long-life hydraulic filter that

best-selling skid-steer loader

Selectable Joystick Controls.

lasts up to 1,000 hours — 500

in the Middle East. Its immense

The 1.8l engine in the S450

hours longer than the S130.

popularity has led the machine

features a non-DPF engine

The S450 is also available

to acquire legendary status.

solution. In addition to

in tracked version as the

So how do you improve

eliminating the need for a DPF,

T450 compact track loader.

upon a legend? And what

the new engine used in the S450

With a width of 56 inches

do you improve it with?

loader has increased torque. This

when paired with a bucket,

increase in torque is produced

the T450 is also designed

over a wide range of engine rpm.

to work in tight spots.

The people at Bobcat’s Dobris plant have answered both.

According to Bobcat’s Gaby

You improve upon a legend

The machine’s system

by listening to the customer

monitors coolant and oil

Rhayem: “The S450 is the

and doing it even better the

temperatures and manages

best-selling skid-steer loader

next time - with the S450. The

the engine to prevent them

by far in the entire Middle East.

new legend. In the making.

from reaching a point where

In this it follows the footsteps

the machine must be shut

of the model it replaces, the

feet wide and designed to

down. Air conditioning is now

S130, which was also the

work on tight jobsites. There

an available option for the

runaway best seller in the

is a 20% increase in auxiliary

S450, as well as the optional

region. The S450 is an even

hydraulic pressure in the 49hp

deluxe instrumentation

better machine and it has shot

machine when compared to

panel, which monitors loader

right to the top of the best-

the S130, as well as a non-diesel

functions, including fuel

sellers list, where it belongs.”

particulate filter engine.

consumption and keyless start.

With the care and attention

The hydraulic performance on

lavished in the manufacturing

the S450 has an optional

the M-Series has a 3,300 psi,

process at the Dobris plant,

two-speed drive with a top

which provides a 22% increase

along with the penchant for

speed of 6.5mph in low range

in attachment performance.

quality, it’s no surprise!

The S450 is less than five

Featuring a radius-lift path,

33 the machine and then to check it once the machine has done its work,” says Remory.

Once the metal is cut and bent in the designated ‘islands’, it then moves along what Bobcat calls the “weld moving lines”. This further consists of islands and sub-assemblies where more parts are added and the various components take shape.

“We have a chart that lists all the components a particular machine needs. A designated person goes to our warehouse with a cart to bring the components. Just like a Lego structure, he stocks up his cart with the components, piece by piece, and then brings it to the first island. And then the chart goes along with the cart as it goes from island to island, the workers take the pieces that they need and use them to build the machine, until finally the cart is empty,” Remory explains.

“The warehouse is our supermarket, where workers come with their chart to ‘shop’. What they need they put into ‘Bento boxes’ with a designated space for each separate component that will be used in assembling a machine, down to the last station or island. And when all these different islands have made their subassemblies, these sub-assembled pieces go to the main paint line, which is probably one of the most vital points in the assembly process for making a Bobcat a Bobcat.”

But before we can come to that allimportant paint line, there are other key areas of the machine to lavish care over. Plant manager Frank leads CMME to one such area – the transmission assembly.

“So, here you can see the final operation on the transmission. The transmission belt is moving, combined with assembly processes and weld processes. The tightening of the critical joints on the hubs is automated, done by an electronic device. All data from every transmission built here is stored and in case we need to look at a transmission down the line for whatever reason, we can find the exact date when that transmission was assembled.

It’s connected to the serial number of the machine and the record is stored for several years to check if something is necessary or some data is required,” he says.

“The internal components of the transmission are most critical to get right, so we have sub-assembly of drive motor carriers, which is semi-automatic, and then we have again a really controlled tightening procedure with devices that collect all data necessary and also assist the operator to complete every operation from start to the end. This is a mistake-proof technology and we also have records of each operation, so in case we find any non-conformities, we can always come back and find the root cause.”

With a view to increasing productivity,

34

COVER STORY JULY 2018

“Industry standard is around 700-800 hours of resistance; had we achieved 750 it would have been enough.

But due to the tough regions our machines operate in, like the Middle East, we kicked it up several notches to 1,000 hours” Bobcat embarked on a new project last year to introduce robotic cells on welding lines, Frank explains. This means most of the welds are now done robotically, further improving precision and quality.

Some of the critical welding still takes place by hand, though – by skilled and experienced hands. “There is an especially high quality expectation on some parts of the transmission, such as the central part, which holds the oil for the lifetime of the transmission. So, the most skilful welders are in this station,” says Frank.

“At the end of the transmission subassembly process, there is a quality check where we pressurise the transmission and check it for potential leaks. In case a transmission doesn’t have sufficient sealing, it’s fixed immediately. The test at the end of the transmission line cannot release a transmission unless it is perfect in all respects.”

When all the sub-assemblies, such as the transmission, main frame of the loader and lift arm, are done, everything comes to the paint line – Bobcat’s pride and joy at Dobris and among the most critical process that gives the machines their quality and durability.

“The paint line is over a kilometre long and mostly automated. There are two main stages – the E-coat and the powder coat. First, we apply the E-coat of liquid paint to the parts

and then we paint them with the powder coat.

So, it’s two layers of paint,” explains Remory.

“In the paint line a part is first washed, cleaned and de-greased. Then it goes into a bath with the liquid paint to get the E-coat.

The E stands for electrostatic, so after the part is immersed in the paint bath, the paint and the part get charged differently, causing the paint to bind fast to the surface of the metal.

And then it goes into an oven to bake at 200 degrees Celsius, which enables a very secure bonding of the paint to the part body. Then it’s cooled. The E-coat forms a base protective layer on the metal, improving durability.”

The last layer is the powder coat, where Bobcat’s standard white, black and red colours are applied, or even other colours based on customers’ orders. “The powder coat line is semi-automated where the white coat, the main colour of Bobcat, is sprayed on. The process for the application of other colours is manual, and it’s the only part of the entire painting process that is done manually; the rest is all automated,” Remory says.

Quality control is especially stringent in the painting process. Explaining the tests conducted after painting, Marcal Pedrao, director of Operations and Supplier Quality, says: “To test the paint job, a painted component or part spends 1,000 hours in a

From laser cutting of the sheet metal to automated paint lines, Bobcat makes full use of technology for quality production, though skilled and experienced hands also play their part.

salt chamber, immersed in a brine solution, which is a very aggressive corrosion agent.

The paint’s resistance to corrosion from the salt is tested and measured. With this, Bobcat achieves a level of corrosion resistance greater than its competitors.

“Industry standard is around 700-800 hours of resistance; had we achieved 750 it would have been enough. But due to the tough regions our machines operate in, like the Middle East, we kicked it up several notches to 1,000 hours.

“This entire painting process, including the automation, is a new upgrade at the plant, and its purpose is not only to make the machines look nice in our colours, but also, more importantly, it’s a vital part of the entire quality proposition of Bobcat, as it improves durability. With this we ensure that Bobcat’s paint resistance is way above industry average. Every layer gets a bake in the oven after application, so from entering the paint line to leaving it, each part spends around five hours in the painting process.”

After painting, the components move on to the final assembly lines. The hoses, connectors and electricals are now installed and connected. The final line is also designed for flexibility as a mixed model assembly. This means that while the lines for loaders and

35

QualiTY COnTROlS

stringent at every step The drive to get the best

which there is another check.

and the display monitor inside the cabin is displaying all

quality starts at Bobcat’s Dobris

But the biggest and most

facility even before production

important quality check takes

information as it should. Then

starts. The sheet metal that

place right at the end of the

they check the unit’s working

is delivered to the plant is

final assembly process when

group, like the loader arms

inspected for quality right at

a finished machine rolls off

and buckets, which are moved

the beginning so that only the

the line. The last station of

high and low, left and right,

flawless raw material is passed

production is the quality

articulated up and down.

onto the production floor.

station, where there is a four-

After that there are quality checks all along the production process, at the end of every

“Then the machine is taken

pronged test awaiting each

outside to a simulated work

and every unit produced.

site and run vigorously for 20

Operations and supplier

minutes like it would run at

important stage. The first of

quality director, Marcal

a normal job-site to test its

these is right after the cutting

Pedrao, elaborates: “The

movements and other functions.

and bending process, when

final check is divided into

Then they do the fourth part of

the welding is done. The vital

four parts: the first is a visual

the test, for which they bring the

components, such as the

check, where the inspectors

machine back inside the plant

transmission, receive their own

walk around a finished

and check all its liquid levels,

quality checks. Every completed

machine to visually ensure

such as hydraulic oil, coolant,

transmission assembly is

there are no flaws, nothing

etc., for pressure, leak and flow.

pressurised to check for leaks

is missing and everything

and only moved on when found

is properly assembled.

flawless. Then, once the quality

“After this the electrical

“When everything is marked ‘Ok’ on the checklist, which has around 60 points depending on

checks are done after the welding

functions are checked. They go

the model type, they give it the

line, the components go for their

into the cabin and check if all

all clear. This process is done

five-hour painting process, after

the connections are complete

for every single machine.”

excavators are different, each line handles a variety of loaders or excavators.

“This requires some extra training and skills from the operator, but it gives us flexibility,” says Remory. “The workers know what machine is next and at that point in time they receive the parts for that particular machine under our just-in-time manufacturing process that cuts down on inventory.”

This is also where the engine is mated to the frame. For the Middle East and other nonregulated markets, Kubota engines are used, which are supplied to each engine assembly point when it arrives at that stage, in keeping with the just-in-time process.

“A loader is built here in 11 steps, each at one station of the final assembly line. For the excavator line it’s 10 steps. The track time is 30 minutes, which means every half an hour a finished loader comes off the line and the whole line moves ahead by a station. The last station where every finished machine stops for its mandatory 30 minutes is the final quality check, where quality experts go through a long check-list of things that need to be inspected and certified up to Bobcat standards,” Remory says. (See box) “Only after each and every machine has been rigorously inspected and tested, and has passed with flying colours, is it fit to be a Bobcat.”

36

ConCrete pumps JULY 2018

PumPed uP Performance Longer and stronger booms, higher quaLity of components for more reLiabiLity and increased deaLer support characterise the region’s mobiLe concrete pumps sector, its major pLayers teLL CMME

“We have a 10,000sqm facility with a big yard and a big stock of machines, and with a hub for spare parts, where we have more than $4-5m worth of inventory covering our whole range in the entire region”

37 Italian concrete specialist CIFA has a threepronged range with Carbotech, Steeltech (below) and Classic models.

The last two are among the GCC’s favourite pumps.

W

hether it’s boom times or lean times, the GCC region still keeps the wheels of its construction industry turning – albeit at varying speeds – with projects of various natures. This means a demand for concrete, which in turn means the wheels of another sort turning as well – the mobile concrete pump.

Part of the three-pronged concrete ecosystem, comprising production, transportation and delivery – or, in equipment terms, the batching plant, the transit mixer and the pump – it is a vital part of the three.

At Italian giant CIFA, one of the biggest names in the pumps and concrete equipment business. Wajih Eit, GM, Zoomlion Gulf, the owners of the CIFA brand, tells CMME that CIFA is in the market with three product lines for its mobile pumps – the Classic, Steeltech and top-of-the-line Carbotech.

“The demand in the region in the last few years is for the long boom pumps. You need space to open the long booms and here there is space. With a long boom you can reach not only vertically but also pump from a far distance horizontally and cover the whole job-site. The standard model that is most requested, and I think will always be requested, is the 42m and then we move to the above-50m booms,” Eit says.

“CIFA has perhaps the most complete line-up of models in the market with our Carbotech, Steeltech and Classic lines. As the name implies, in the Carboteach range, which is our most advanced and carries our patented technology, large sections of the boom are made of carbon fibre The range is also about the advanced software and electronics inside - our Smartronic suite. And the big advantage is the light weight. So, we have the longest boom in this range that can be mounted on an 8x4 truck, that is the 60m. Of course, we also have the 80m and 100m boom models in the Carbotech range with other truck axle configurations. The Carbotech range is more for advanced markets as it is a high-technology product but we know that sooner than later it will gain popularity in this region as well.

“The Steeltech line is our standard one, with which we are competing with other European suppliers here, as it’s 100% made in Europe. The best-selling models are the 36m, 42m, 48m and 55m and we are going to bring in a new model at the end of 2018 - a 63m Steeltech made in Italy.

“Our third line is called Classic. Even though it is CIFA, it’s made in our China production facility, and it is dedicated to those customers that prefer a value model. It provides good quality at a lower price point and allows us to compete with the Asian suppliers. It’s a basic pump with a simpler configuration but very suitable for the Middle East and we are doing brisk business with it here.”

There is no compromise on quality, however, because it still is a CIFA branded product, Eit points out. “When we launched it, we differentiated our lines and made it clear that Steeltech is a European-made product and the Classic is priced lower only because of the lower cost of manufacturing in China. All the components of the Classic line are from the same global suppliers - for example, the hydraulic pump is from Bosch - but it enjoys a cost advantage of being built in China.”

Another big development at CIFA, is that it will be the Zoomlion Group’s only concrete productss brand for the

38

ConCrete pumps JULY 2018

Middle East, and Eit explains: “We have both Zoomlion and CIFA in our stable, and our facility in Dubai’s Jebel Ali Free Zone is a joint one, but so far as our concrete products go in the region, we only have one brand – CIFA. “Under Zoomlion Gulf, we have a 10,000sqm facility, with a big yard and a big stock of machines, and with a hub for spare parts, where we have more than $4-5m worth of inventory covering our whole range and in the entire region. From here we handle all the parts and service requirements for the entire Middle East with our technical and service team.”

In terms of customising technology to local requirements, Eit says CIFA is the only manufacturer that has both closed-circuit and open-circuit pumping unit options.”But for this region we are only going with the open-circuit, which is very suitable for the hot weather and easier and cheaper to maintain. The pressure generated is slightly lower than the closedcircuit, but what you get is less complications because of the reduced electronics. It also tackles the hot weather better because it has more oil compared to the closed-circuit but at a much lower pressure, which means the oil does not heat quickly.

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

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

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

“Putzmeister in general is the only manufacturer who invested $30m in a testing facility where we are testing each and every component up to a lifetime of 10 years. So, considering this, we are sure that in the long run we are the cheapest. The initial cost might be high, but the long term total cost of

German biggie Liebherr is gaining in popularity with new innovations such as the XXT outrigger system, while compatriot Putzmeister focuses on total quality and service.

Liebherr XXt

exceLLing in technoLogy Liebherr’s exclusive XXT outrigger

for narrow

system is an innovation that

support and

provides specific advantages for

flexible set-

everyday applications on building

up angles.

sites. With the narrow support

The design

option, the front outriggers can

also reduces

be extended up to the front of

overall weight

the vehicle, allowing a greater

by eliminating

working range of up to 70%. This

the fulcrum

also enables pumping concrete

for a separate front outrigger.

over the operator’s cab.

Stability is also enhanced by the

says Liebherr’s Ali Kasem.

“It also gives a lot of flexibility,

XXT design, as is working over the

because you can open it at a very

direct power transmission from

roof of the operator’s cab even

small angle and you don’t need

boom to outrigger. Also, the XXT

with the narrow support option.

to open at a full angle. You can

Other advantages include

design ensures that no forces are

“In the XXT, we actually have the

also move it wherever you want.

directed towards the vehicle frame/

front outrigger sitting inside the

Let’s say there is an obstacle and

chassis by the distributor boom.

rear one. So when you close the

you cannot open the outriggers

outriggers, the front leg closes into

fully and you can just open one

of the front outrigger, the truck

the rear one, which is made of two

a little bit. In such a situation in

is ready to pump. The front and

long pieces with a hollow space

the XXT, if you can open one, the

rear support rotate around the

towards the base. This is also an

other will come out of it and form

same centre of rotation or pivot,

advantage because then you have

an acute angle from the same

providing optimum possibilities

less deflection and less vibration,”

pivot - and you are set to pump.

With only a simple telescoping

39

A miLestone in pumping

60 years of putzmeister Putzmeister is marking its 60th

company added subsidiaries and

hydraulically driven two-cylinder

anniversary this year, celebrating

sales offices in other countries –

piston pump combined with the

six decades of global renown in

including France, Spain, the UK, the

flapper system (1969), Putzmeister,

the production of concrete pumps,

USA, Brazil, South Africa, Singapore,

brought something new to the

mixers and other equipment.

China, Korea, Japan, Russia,

market despite being a newcomer.

Founder, Karl Schlecht, started

India, the UAE, Iraq and Turkey

Setting a world record of 310m

the company from his father’s

– enabling Putzmeister to act

in high-rise concrete pumping at

garage while he was a mechanical

internationally. Furthermore, the

a Frankfurt tower in 1977 brought

engineering student and, from

company’s sales team is supported

Putzmeister global recognition.

the outset, stuck to the principle

by well-trained dealers and services

Among other records it has set

that contact with the customer

centres around the globe.

since are: a new world record in

did not end upon delivery of the

Putzmeister extended its range

high-rise concrete pumping at

machine, but was also maintained

of products with the development

Dubai’s Burj Khalifa, with a height

in the period following delivery.

of concrete pumps in the 1960s.

of 606m in 2007; introducing a

Higher pressures, larger pump

new truck-mounted pump with a

requires a dense and well-

volumes and even concrete delivery

70m placing boom reach for the

structured sales and service

were only possible, in Schlecht’s

first time ever in 2008; and a new

network, says Putzmeister, and

opinion, if previous design

Guinness World Record for the

the company began establishing

principles were fundamentally

world’s largest continuous concrete

its own branches in Germany as

questioned and new paths taken.

delivery of 19,793m³ in 42 hours

early as the 1960s. In the 1970s, the

With the concept of a hydro-

for the Geepas Tower in the UAE.

Closeness to the customers

ownership of Putzmeister is still the best. We have adjusted the scope of supply to the local requirements. So, we have specifications built in our machines only for the GCC market.”

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

So this increases the reliability and safety of Putzmeister pumps.”

Meanwhile, at another European manufacturer, Leibherr, the good times are beginning to roll in. Ali Kassem, regional sales manager, Concrete Equipment Division Middle East, tells CMME that 2017 was a year that began on a tough note but ended well – a sentiment that has carried on to this year, too.

“Pumps is a new business for Leibherr,” he says. “We came into this category when Liebherr acquired German pump specialist Waitzinger some five years ago. We have only sold pumps in Saudi Arabia in the GCC in the past through Leibherr’s KSA arm, but things are looking better for the rest of the region now with more deliveries planned for the coming months in the UAE,” Kassem says.

Like others, Liebherr, also has its own patented technology in its pumps, namely the XXT outrigger system, which reduces the four pivot points for the four outriggers to only two with a front outrigger that collapses into the rear one. This greatly improves stability and the ability to operate in confined spaces, including the ability to pump over the head of the truck cab, says Leibherr (see box). “Our range consists of the 37, 43, 47 and 50m models, all XXT. Of these, we’ve delivered some 43m models in the UAE recently,” Kassem says.

Schwing Stetter, another German concrete specialist, meanwhile, has the S38SX Reptor among its latest truck-mounted concrete pumps suitable for a wide range of applications and with a boom that it says redefines the 30m class. The S38SX has wide boom opening angles and high boom manoeuvrability, resulting in flexibility on job sites. The S38SX Reptor is equipped with Super-X outriggers that offer high stability even when they are operated in low space requirements where full extension is not possible. On the 8x4 chassis mounted on a larger 5,150mm wheelbase, the truck also carries a long stroke pump kit with 2.50m delivery cylinders, which enables it to save 20% strokes for less wear and tear.

With signs of demand returning to the region’s market and manufacturers gearing up with innovative products and after-sales solutions, the truck mounted concrete pumps sector is poised to gain even greater strength in the Middle East.

40

THE LAST WORD JULY 2018

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