Big Project ME Concrete Supplement 2016

A supplement of:

CONCRETE REPORT

green concrete Why the uae muSt look at green concrete in a SeriouS manner ggbfs examining the StrengthS of ggbfS and itS efficiencieS in concrete

building for the long term

Sustainability and durability are the new watchwords for the region’s construction industry

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Introduction

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Going for green

4

AN INTRODUCTION TO GGBFS

W

hen putting together this year’s Concrete Report, one of the most intriguing aspects we found was that a number of companies are quite apprehensive about current conditions in the market. While everyone expects certain markets to improve once construction kicks into gear on megaprojects, the current reality is that concerns over oil prices and slashed budgets dominate the industry’s thoughts.

The emphasis is very much on sustainability and durability, with companies looking to adopt methods and technology that will give their projects a longer shelf-life, with less maintenance and more efficiency.

Suppliers and manufacturers are responding to this, with more and more new products being released to take advantage of this shift in thinking.

It seems that going green is now the only way to go. for the concrete industry.

Tel: +971 4 440 9100 Fax: +971 4 447 2409 www.cpimediagroup.com

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8

DEVELOPING GREEN CONCRETE

20

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POWER PUMPERS

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Founder Dominic De Sousa (1959-2015) Printed by printwell printing press LLC A supplement of Big project Middle East © Copyright 2016 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.

Gavin Davids editor gavin.davids@cpimediagroup.com Concrete Report 2016 1

Overview

Investment worth $18.1bn In the manufacture of cement, lIme and plaster In the Gulf Report finds investment in sector increased between 2011 and 2016 Investment in the manufacture of cement, lime and plaster in the GCC reached a total of $18.1 billion in 2015, according to experts from the Gulf Organisation for Industrial Consulting (GOIC).

Speaking in a report published in June 2016 by the Gulf Industrial Knowledge Centre (GIKC), the experts explained that the number of GCC factories

producing cement, lime and plaster grew from 59 in 2011 to 69 in 2016 – a compound annual growth rate (CAGR) of 4%.

In addition, there has been a surge in investment, from $15.4 billion to $18.1 billion, a CAGR of 4.1% for the same period.

Meanwhile, the segment’s labour force increased from 25,305 to 26,469 during the same period, the GIKC report added.

Data

Additional data from the GOIC’s Industrial Information Unit showed that the manufacture of cement, lime and plaster represented approximately 2.4% of the total factories, 47.3% of the total investment and 9.7% of the total labour force in the field of building materials manufacture in 2015.

These figures related to the

manufacture of cement, lime and plaster include the manufacture of clinkers and hydraulic cements, including Portland, aluminous cement, slag cement and superphosphate cements, the report said. They also cover the manufacture of quicklime, slaked lime and hydraulic lime, and the manufacture of plasters of calcined gypsum or calcined sulphate.

2011

2012

2013

2014

2015

59

62

62

67

69

Investment (USD millions)

15,435

15,769

16,034

17,526

18,102

Labour force

25,304

24,619

24,079

25,681

26,469

2012

2013

2014

2015

CAGR (5 years)

Growth rate of factories manufacturing cement, lime and plaster

5.1

0.0

8.1

3.0

4.0

Growth rate of investment in the manufacture of cement, lime and plaster

2.2

1.7

9.3

3.3

4.1

Growth rate of labour force in field of cement, lime and plaster manufacture

-2.7

-2.2

6.7

3.1

1.1

Factories

Data

2 Concrete Report 2016

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Industry Insight

An IntroductIon to GGBFS Ishan Aggarwal of Super Cement looks to quantify the strengths of ground granulated blast furnace slag and evaluate its efficiencies in concrete

4 Concrete Report 2016

t

he use of supplementary cementation materials is well accepted, since it leads to several possible improvements in the concrete composites, as well as the overall economy. Many of the governments all around the world have slowly understood the requirement to adapt and enforce the usage of these ecofriendly supplementary products to their concrete manufacturers.

The present article is an effort to quantify the strength of ground granulated blast furnace slag (GGBFS) at various replacement levels and evaluate its efficiencies in concrete. Cement with GGBFS replacement has emerged as a major alternative to conventional concrete and has rapidly drawn the concrete industry’s attention due to its cement savings, energy savings, cost savings, and environmental and socioeconomic benefits. Since the grain size of GGBFS is less than that of ordinary Portland cement, its strength at early ages is low, but it continues to gain strength over a long period. What are the benefits of this product for the government, environment, manufacturers and contractors?

What is GGBFS?

Blast furnace slag is a by-product of iron manufacturing. Iron ore, coke and limestone are fed into the furnace, and the resulting molten slag floats above the molten iron at a temperature of about 1,500-1,600ÂşC. The molten slag has a composition of 30-40% silicon dioxide

Industry Insight

(SiO2) and approximately 40% CaO, close to the chemical composition of Portland cement.

After the molten iron is tapped off, the remaining molten slag, which mainly consists of siliceous and aluminous residues, is then rapidly waterquenched, resulting in the formation of a glassy granulate.

This glassy granulate is dried and ground to the required size and known as ground granulated blast furnace slag (GGBFS).

The production of GGBFS requires little additional energy compared with the energy required for the production of Portland cement. The replacement of Portland cement with GGBFS leads to a significant reduction of carbon dioxide gas emission. GGBFS is therefore an environmentally friendly construction material which can be used to replace as much as 80% of Portland cement when used in concrete.

GGBS concrete has better water impermeability characteristics as well as improved resistance to corrosion and sulphate attack. As a result, the service life of a structure is enhanced and maintenance cost is reduced. High volume eco-friendly replacement slag leads to the development of concrete which not only uses the industrial waste but also saves significant natural resources and energy. This in turn reduces the consumption of cement. The optimum GGBFS replacement as cementation material is characterised by high compressive strength, low heat of hydration, resistance to chemical attack, better workability, good durability and cost-effectiveness.

Benefits of using GGBS in concrete Sustainability

It has been reported that the manufacture of one ton Concrete Report 2016 5

Industry Insight

Strength gain in concrete mixes 7 days

28 days

Heat produced (cal/g) OPC+GGBFS

90 days

120

120

100

100

80

80

60

60

40

40

20

20

100% OPC

50% OPC + 50% GGBFS

of Portland cement requires approximately 1.5t of mineral extractions together with 5,000MJ of energy, and generates 0.95t of CO2 equivalent. As GGBFS is a by-product of iron manufacturing, it is reported that the production of one ton of GGBFS generates only about 0.07t of CO2 equivalent and consumes only about 1,300MJ of energy.

Strength

GGBFS concrete gains strength more steadily than equivalent concrete made with Portland cement. For the same 28 days’ strength, GGBFS concrete has lower strength at early ages but in the long term its strength is greater. The table shows the strength gained by three different mixes of concrete.

Colour

Ground granulated blast furnace slag is off-white in colour. This whiter colour is also seen in concrete made with GGBFS, especially at replacements greater than 50%. The more aesthetically pleasing appearance of GGBFS concrete helps soften the visual impact of large structures such as bridges and retaining walls. For coloured concrete, pigment requirements are often reduced with GGBFS and colours are brighter.

6 Concrete Report 2016

30% OPC + 70% GGBFS

Setting time

The setting time of concrete is influenced by many factors, in particular temperature and water/cement ratio. With GGBFS, the setting time is slightly extended, perhaps by about 30 minutes. The effect is more pronounced at high levels of GGBFS and low temperatures.

An extended setting time is advantageous in that the concrete remains workable for longer periods, resulting in fewer joints. This is particularly useful in warm weather.

Durability

Concrete containing GGBFS is less permeable and chemically more stable than normal concrete. This enhances its resistance to many forms of deleterious attack, in particular: • Disintegration due to sulphate attack • Chloride-related corrosion of reinforcement • Cracking caused by alkali silica reaction Consistency

While concretes containing GGBS have a similar or slightly improved consistency to equivalent Portland cement concrete, fresh concrete containing GGBS tends to require less energy for movement.

1 Day

“The production of GGBFS requires little additional energy compared with the energy required for the production of Portland cement. The replacement of Portland cement with GGBFS leads to a significant reduction of carbon dioxide gas emission”

OPC

2 Days

3 Days

This makes it easier to place and compact, especially when pumping or using mechanical vibration. In addition, it retains its workability longer.

Early age temperature rise

The reduction involved in the setting and hardening of concrete generates significant heat and can produce large temperature rises, particularly in thick section pours. This can result in thermal cracking. Replacing Portland cement with GGBS reduces the temperature rise and helps to avoid early age thermal cracking.

The greater the percentage of GGBS, the lower the rate at which heat is developed and the smaller the maximum temperature rise. The chart below shows the difference between the heat produced by OPC and by a mix of OPC & GGBFS. Advancements in today’s world in the concrete industry benefit every aspect of the economy, leading to a healthier and more economical way of construction. Developing countries have understood these benefits, and with their support, we as manufacturers are proud to serve the people with an eco-friendly product.

We believe we have a duty to hand over a greener world to our coming generations.

Green Concrete

Developing green ConCrete in the UAe Dr Abdul-Rahim Sabouni, CEO of Span M Consulting and a Fellow at CIOB, explains why it is essential for the UAE to begin looking seriously into the development of green concrete solutions 8 Concrete Report 2016

Green Concrete

Concrete Report 2016 9

Green Concrete

W ith more than 10 billion tons produced each year worldwide, concrete is by far the most important building material. The concrete industry is the largest user of natural resources in the world, and Portland cement, a key ingredient in most conventional cement, accounts for roughly 5% of all carbon dioxide gas generated by human activities worldwide.

Each year, concrete production uses 1.6 billion tons of Portland cement, 10 million tons of sand and rock, and 1 billion tons of water. The production of Portland cement is by far the largest user of energy in the concrete construction process, accounting

for 85% of the total energy required. The manufacture of cement produces large amounts of air pollutants and dust. For every ton of cement clinker produced, almost a ton of carbon dioxide, a greenhouse gas, is released into the atmosphere.

The concrete industry has to be able to offer solutions to the demand for green products to be an integral and responsible partner to local and global environmental concerns. Concrete, as with other building materials, has embodied energy: it takes energy to manufacture and construct concrete building or structure; however, concrete’s lower embodied energy from cradle to cradle can be used smartly.

Developing green concrete is moving from being a preference to becoming a priority worldwide, and the Middle East is no exception. Greening of concrete has often been interchangeably used in reference to green

“The UAE, with its large construction projects, produces and consumes concrete, as most of its structures are made of reinforced concrete.

Improvement in concrete greening will have a significant impact due to the large volume� green becomes a priority Developing green concrete is moving from being a preference to becoming a priority worldwide.

building, green construction and sustainable construction.

This is mainly due to the fact that concrete is the dominant construction material in the region. In the UAE, demand has been slowly increasing since 2008 and is currently estimated to be around 19 million tons; however, the 12 cement factories in the UAE have a capacity of up to 39 million tons per year.

The UAE, with its large construction projects, produces and consumes concrete, as most of its structures are made of reinforced concrete. Improvement 10 Concrete Report 2016

Green Concrete

government orders In November 2014, Dubai Municipality mandated the use of sustainable concrete for all new projects, making it compulsory as of April 2015.

in concrete greening will have a significant impact due to the large volume. Sustainable concrete structures ensure that the total environmental impact during their lifecycle will be minimal.

Government authorities in control of the construction industry in the region are becoming increasingly strict in imposing environment friendly regulations for all types of structures, with concrete greening in the forefront of progress aiming at improving the environmental impact of the construction industry.

Concrete must keep evolving to satisfy the increasing demands of all its users. Sustainable concrete uses green materials which have low energy costs, high durability and low maintenance requirements, and contain a large proportion of recycled or recyclable materials. Green materials also use less energy and resources and can lead to high-performance cements and concrete. Sustainable concrete should be produced with little waste, be made from some of the most plentiful resources on Earth, produce durable structures, have

a very high thermal mass and be made with recycled materials.

Developing green concrete in the UAE is in line with the increased emphasis on ecofriendly sustainable economy. This is clear from several eco-friendly initiatives recently introduced by the UAE government, including two major initiatives relevant to developing green concrete: Green Building regulations in Dubai and Estidama in Abu Dhabi.

Dubai Green Building Regulations: As part of the Dubai 2020 urban master plan to become one of the most

environmentally sustainable cities, Dubai Municipality initiated in November 2014 a circular mandating the use of sustainable concrete for all new projects, made compulsory as of April 1 2015, in order to reduce carbon emissions and strategically position the Emirates on the green building and urban planning scene.

According to research cited by the municipality, the production of one ton of OPC is accompanied by the emission of 1.1 tons of carbon dioxide (CO2), in addition to the other harmful Concrete Report 2016 11

Green Concrete

side-effects due to the production of huge amounts of dust, as it is estimated that each ton of OPC produces 164kg of dust pollution.

The new rule means all Dubai projects must use ecofriendly concrete. The initiative concentrates on the use of eco-friendly Supplementary Cementing Materials (SCMs) to replace, in varying ratios, the common Ordinary Portland Cement (OPC) used in most Dubai buildings. The most important and commonly used SMC materials are: Ground Granulated Blast Slag (GGBS), Fly Ash (FA), Silica Fume (SF) and Fiber Glass (FGL).

Substituting OPC with SCMs cuts CO2 emissions by 80% while increasing resistance to salts, which is an important factor due to the soil composition of the UAE. The materials also improve the thermal insulation of concrete, making them more suited to extreme heat. By comparison, SCMs are cleaner, more durable and competitively priced, if not cheaper than OPC. Abu Dhabi Estidama Regulations: In line with the Abu Dhabi 2030 master plan, in 2008 the Abu Dhabi Urban Planning Council launched Estidama, an initiative which aims to make the country fully sustainable by targeting residential areas and buildings, government entities and commercial buildings to meet environmental standards. All new developments and construction projects in the UAE must receive permission from the council to show they have met with environmental standards. These include energy savings through building insulation, solar-powered water heating systems and using eco-friendly refrigerants which have lower waste emissions.

The initiative also encourages the use of local construction materials. When architects, 12 Concrete Report 2016

Building sustainable Developing green concrete allows the construction industry to not only retain and enhance the benefits of concrete, but will also help the UAE build more sustainable developments.

“Substituting OPC with SCMs cuts CO2 emissions by 80% while increasing resistance to salts, which is an important factor due to the soil composition of the UAE”

engineers and contractors look at the environmental impact of their projects in light of Abu Dhabi’s mandated sustainability standards and to achieve higher numbers in the Estidama Pearl Rating System, concrete is one of the first places they look.

Concrete will continue to be the main construction material in the UAE despite all environmental concerns.

Developing green concrete makes it more attractive and adaptable to the sustainable economy in the UAE. Even in Masdar City, one of the world’s most important eco-friendly flagship projects and the world’s first zero-carbon city, concrete is used as the construction material of its structures.

However, there are challenges to using concrete in the city, and to deal with conventional

concrete’s inherently high carbon footprint, developing green concrete becomes a must. In addition to the use of 40-60% SMC, special other measures need to be taken – such as minimising the use of materials for formwork, locating the batching plant on-site, recycling waste concrete crushed onsite and used for roads, and reducing energy consumption – at every step of the process of concrete construction.

One major reinforced concrete project currently under construction in Abu Dhabi is Abu Dhabi Airport Midfield terminal building. It follows a sustainable approach to construction developed by Abu Dhabi Airports, in coordination with the Environment Agency of Abu Dhabi (EAD), the UPC and the Estidama, to address local environmental factors. The Midfield terminal building has achieved a 3 Pearl design rating and is now the highest rated airport in the GCC and the largest single building to ever be rated.

Some of the main greening measures implemented are the use of structural and reinforcing steel with recycled content; 20% of total material by cost value is sourced regionally, only recycled aggregate is used for backfilling, and a 20% reduction in water consumption is achieved through the use of recycled water.

Concrete is a uniquely useful building material well suited to this region’s vast infrastructure and building needs, but it traditionally has come with an enormous environmental cost.

Developing green concrete is helping find a third way that not only retains or even enhances the many benefits of concrete, such as its durability, longevity and heat storage capability, but helps the UAE build more sustainable developments.

If it’s Cement

it’s “Super” Super Cement Manufacturing Company L.L.C. is a Granulated Blast Furnace Slag (GBFS) grinding, quick lime and Hydrated lime Manufacturing Unit, which is located in the Industrial City of Abu Dhabi (ICAD-1).

international markets. The company has recently started manufacturing high grade Hydrated Lime in the same facility with a capacity of 7,000 tons Super Cement Manufacturing Co. is the per month. biggest importer of high quality Granulated The grinding capacity of Super Cement Blast Furnace Slag from Japan.

Company is 1,400,000 metric tons of slag Blast Furnace Slag is a by-product of iron per year. The company has been promoted Mr. Sanjay Aggarwal and steel manufacturing industries but it jointly by the following eminent industrialists: is a young and dynamic is an important value-added ingredient of Mr. Ali Hamel Al Ghaith (UAE National) entrepreneur of Indian origin Cement Concrete that is used in all modern Mr. Sanjay Aggarwal (Indian National) who has vast experience operating construction. successful businesses in the field of Steel Mr. Ali Hamal Al Ghaith belongs to Al Ghaith Rolling Mill, Coke Oven, Ferroalloys and Super Cement is currently manufacturing Mining Operations. His dynamic leadership Quick Lime in the form of lumps Holding PJSC (AGH), which is a major family and hard work are attributed to the successful and powder at the capacity business house in the Middle East. Mr. Ali is commissioning and operation of a structural of 18,000 Tons per actively involved in various businesses such month for the as Caustic Soda in Abu Dhabi, oil and gas steel rolling mill of 120,000 ton/annum local and construction through Al Ghaith Oil & Gas capacity to meet the requirement of an integrated steel plant in India. He is on the 33-34 FR6, ICAD-1 Mussafah Industrial Area Construction Co. L.L.C, Al Ghaith Shinyang path to expanding at a rapid pace both locally P .O. Box 132595, Abu Dhabi Shipping and Al Ghaith Salt. and internationally.

Tel: +971 2 5502458 Fax: +971 2 5502203 Email: ishan@supercement.co

www.supercement.ae

Concrete Admixtures

Big Project ME speaks to Wicus va n Wyk, Admixture sales manager for the Gulf States at BASF, to find out why the company ’s dual purpose corrosion inhibitor admixture mig ht just be a game-changer for the concrete in dustry

s u s a g n i t a Cre 14 Concrete Report 2016

Concrete Admixtures

x i m e l b a n i sta Concrete Report 2016 15

Concrete Admixtures

O

ver the last few years the Arabian Gulf countries have seen an unprecedented combination of events that have resulted in the regional construction industry having to face up to some particularly interesting challenges.

Not only does the industry have to deal with slashed budgets and less liquidity in the market due to the fall in oil prices, but following events like COP21, there has been a noticeable shift in attitudes towards the concept of green building and sustainability.

As such, developers are now looking to build projects that last longer and are more durable in the face of the region’s distinctive environmental conditions.

Where before, the average life expectancy for a building was 50 to 70 years, developers are now looking for buildings that can last as long as 120 years.

Furthermore, they also require these structures to be energy-efficient and sustainable, in line with recently introduced government regulations about green building codes.

To help achieve these goals, contractors, consultants and owners are turning to suppliers and manufacturers to create and provide products that will enhance the efficiency and lifecycle of projects, but also provide value for money down the line.

This is where companies like BASF come into play. As the world’s leading chemical manufacturing company, the German firm provides specialised chemicals, performance products, 16 Concrete Report 2016

Key factor Clients in the GCC are now looking at the service iife of a project as a key factor in their spending, Wicus van Wyk says.

functional materials and solutions, agricultural and oil field solutions to help a range of industries with their infrastructure or manufacturing needs.

The company’s Construction Chemicals division is one of its most active segments in the Gulf and it produces concrete admixtures, cement additives, waterproofing systems and many other products for new construction, maintenance, repair and renovation of structures.

BASF’s MasterLife CI 222 is a corrosion-inhibiting admixture.

This state-of-the-art solution has been formulated to inhibit the corrosion of steel in reinforced concrete, and having being patented in 1993, it remains a unique product in the market.

Providing two levels of protection to all types of reinforced concrete, including

“When I came here initially, about 12 years ago, you used to get ranges of 55 to 70 years.

That’s what clients were specifying.

Now you see ranges of 100 to 120 years”

precast and post-tensioned products, the admixture is considered one of the most effective in the market. In order to find out more about the benefits it brings to projects, Big Project ME caught up with Wicus van Wyk, Admixture sales manager for the Gulf States at BASF Construction Chemicals.

“Under our flagship Master Builder Solutions portfolio, the MasterLife range offers products designed to increase the service life of projects. MasterLife CI 222 is an admixture that is organic and mitigates corrosion, extending the lifespan of structures and reducing maintenance and retrofit associated costs.

“If I can put it in simple terms, it provides two levels of corrosion protection. One is by inhibiting and the other by waterproofing.

We have implemented it across the GCC – in Kuwait, Qatar, Oman and the UAE. In fact, we worked on a big hospital project in the UAE where the product was used on the entire sub-structure,” he says.

With clients in the GCC now looking at the service life of a project as a key factor in their spending, van Wyk highlights how admixtures like MasterLife CI222 can help extend the service life of reinforced concrete.

“MasterLife CI222 slows down the ingress of chlorides and moisture into the concrete, and it forms a strong, durable protective film on the reinforcing steel for a second layer of protection. If we consider the Middle East, where there’s high chloride and sulphate content, where most of the areas are completely surrounded by seawater and some areas have high levels of groundwater, then it’s a big issue.

“By adding something like this, you’re basically giving yourself a second shot at protecting the steel in your structures, which then extends the life of that

Concrete Admixtures

steel and therefore extends the time before you really need to start repairing or carrying out maintenance on the structure.”

While most other corrosion inhibitors can have an adverse impact, such as delaying the set time of the concrete pour, which inconveniences the contractor and causes stoppages to work on-site, the dual purpose admixture developed by BASF has been specifically designed to minimise downtime.

Additionally, looking at the

general trend of sustainability in the regional construction industry, van Wyk says that he’s noted a definite upward incline in interest, with developers now looking to see how they can extend the service life of their buildings.

“Service life models are available across the world and they all work on the same principle – you put in your various data, such as where the project is located, what type of environment it’s in, what type of concrete you’re using, what type

of ingredients are being put in, what’s the cover on your steel and so on. The models use all this data to try and predict how long it would take before the building starts to require maintenance.

“When I came here initially, about 12 years ago, you used to get ranges of 55 to 70 years. That’s what clients were specifying.

Now you see ranges of 100 to 120 years. This has become a normal thing. Although clients are realising [that sustainability is the way forward], they are

sometimes reluctant to invest in new systems and solutions.”

While there have been positive moves in terms of awareness and education, van Wyk remains adamant that educating the market must continue.

“We want people to understand that there are solutions for this and that, yes, it will be more expensive initially, but you must really look at it long-term and understand what it can do for your structures. We always try to give clients the complete package

“By adding something like this, you’re basically giving yourself a second shot at protecting the steel in your structures, which then extends the life of that steel and therefore extends the time before you really need to start repairing or carrying out maintenance on the structure”

Stetter GmbH · Dr.-Karl-Lenz-Str. 70 · 87700 Memmingen, Germany · Tel.: +49 8331 78-0 · info@stetter.de

www.stetter.de

Concrete Report 2016 17

Concrete Admixtures

or solution, and this is part of it,” he says, adding that BASF always recommends that all admixtures in a concrete mix come from a single supplier. This includes waterreducing superplasticers and durability-enhancing admixtures.

“This ensures that the chemicals are compatible and that there will be no liability issues in the future.

“So yes, there’s a lot of education required. At BASF we have always been committed to enhancing awareness. We’ve really looked at this as part of BASF overall – to be sustainable and to offer complete solutions. We have seen significant uptake of the Master Builders Solutions over the last year, driven by the region’s focus on sustainable building practices and energy efficiency.

“You must remember that it’s only been five years since the major recession took place across the Middle East. Unfortunately a lot of companies are looking at immediate cost rather than long-term gain. As we get out of this phase, clients are going to be more open to it and we can see it picking up a lot,” van Wyk says.

“Public and private enterprises are increasingly understanding

a second layer of protection BASF’s MasterLife CI222 slows down the ingress of chlorides and moisture into the concrete, forming a strong, durable protective film.

18 Concrete Report 2016

local performance matters BASF has tied up with local universities to test and research their products to ensure that they perform in the GCC environment.

the importance of smart and green building practices. This is evident in their specific demands and their use of high benchmarks of quality through the course of any construction project. They understand that investments will need to be made in the short term,

but that it will be accompanied by benefits in the long run.”

As part of this effort to increase education and awareness, BASF has tied up with a number of local and regional universities to test and research their products and ensure that they

perform in local conditions.

Although MasterLife CI222 was developed in the US, van Wyk explains that BASF has asked local universities to test it according to standards and conditions in the GCC to ensure that the product complies with all standards and requirements.

“The Kuwait Institute for Scientific Research is currently testing MasterLife CI222 to confirm its corrosion inhibiting properties. We’ve previously done this with the American University of Sharjah, where they did the full-scale testing in local conditions and found that our product is fully compliant, and that it actually does what it says – extending service life, protecting steel and slowing the ingress of chlorides into concrete,” he concludes, highlighting just how much emphasis is now being put on the key aspects of sustainability, durability and lifecycle costs.

Product Focus

Specific moulds for projects Pozzolan has the capability to design and create special moulds for clients.

Creating SpaCe

Big Project ME speaks to Andre Mikaeili, general manager at Pozzolan International FZC, about how plastic spacers for reinforced concrete covers can benefit contractors

20 Concrete Report 2016

What does Pozzolan do, and how can it help its clients achieve optimum results on projects?

We may be regarded only as a manufacturer and a supplier of plastic spacers for reinforced concrete cover, but I need to stress that it is our policy to always take one step further for our clients.

As a manufacturer, we have the capability of designing special moulds, and in so many cases we have done it. We have quite a few moulds in our main manufacturing facility which were only used for certain items in projects. We make our clients our first and utmost priority.

Pozzolan International FZC might be a newly established company in the UAE market, but as a brand we have been

present in the UAE and GCC market for the last seven years, and we have done a lot of work to raise awareness within the industry about using plastic spacers on construction projects.

As you know, it is a competitive market, but for us price has not been the only issue. For a long period we have not increased the price of our products, only for the sake of nurturing and fostering the aforementioned culture.

Our vision makes us responsible for the quality assurance of our products and service; therefore, we are always in close contact with our clients to make sure that they are satisfied with the quality. We always listen to them for suggestions

Product Focus

One-time use Most of Pozzolan’s products are designed for one-time use, thereby saving contractors the cost of having to replace them.

regarding modifications in the products for easier usage.

How do Pozzolan products help manage contractor workloads and reduce costs?

Well, the majority of our products are only for one-time use. We are lucky, you may say, but we also have to try our best to keep the prices quite low as well.

Also, we do care about our products being environmentally friendly. The raw material that we use is 100% recycled.

It corresponds to the relevant schemes of LEED and other similar certification, which is a benefit to the contractor and the developer.

How can Pozzolan’s products be adapted to individual projects

“We have been present in the UAE and GCC market for the last seven years and we have done a lot of work to raise awareness about using plastic spacers on construction projects”

and improve efficiency?

As manufacturers, we have the design capabilities to manufacture unique items for individual clients, and as I explained before, we are in close contact with our clients to make sure that they are satisfied with what we deliver, and to take on board their suggestions when it comes to modifying products for specific usages.

What new products are in the pipeline, and what are Pozzolan’s hopes for them?

At the moment, we are developing a new product in our R&D department, which I hope we will be able to showcase during The Big 5 2015, which will help to improve efficiency by eliminating the

use of tie wires. A huge effort in marketing is required to present the innovations and bypass the old-school biases.

Can Pozzolan’s products be tailored to highly specific projects, such as airports and other major infrastructure and transport projects?

Yes. Pozzolan has two specific products, Stool double rebar chair spacer and Eifel double rebar chair spacer, which were developed mainly for the purpose of being used in the aprons [the parking area of airplanes].

Also, we have other heavy-duty items such as pile cage spacers, and also PVC pipe spacers and roll plugs, which are used in roads and bridges, telecommunication and railways respectively.

Concrete Report 2016 21

Concrete Pumps

power pumpers

Precision in the delivery of concrete is of vital importance on any construction site – and even more so in the Middle East, known for tough operating conditions and high customer expectations. Big Project ME looks at how manufacturers of truck-mounted concrete pumps are meeting market demands

22 Concrete Report 2016

I

t’s easy to marvel at the skyscrapers, luxurious hotels, ambitious metro projects and other architectural wonders taking shape across the GCC. But the less glamorous, and sometimes overlooked, aspect of all this construction is the equipment needed to build these projects.

After the financial crisis of 2008, demand for construction machinery nearly ground to a halt as most projects underway found themselves in limbo. Concrete equipment sales suffered a similar fate, and several concrete pumps bought before the crisis lay idle in the ensuing years, explains Jens Bawidamann, regional director at Putzmeister Middle East.

Now, however, as the industry gains traction, business is booming again in concrete pumps. But while the UAE market is currently nearly saturated as far as stationary pumps go, truck-mounted pumps are increasingly in demand.

“We have had extraordinarily good business for our truckmounted pumps, especially for our newer models,” Bawidamann tells Big Project ME, noting that the German manufacturer has been seeing continuous growth in the Middle East over the past five years, with especially strong sales in the GCC. Putzmeister has been finding success with truck-mounted pumps in longer boom lengths, and the company has launched new machines in the past few years in the 30m, 40m and 50m classes. “They are more userfriendly, efficient and maintenance-

Concrete Pumps

friendly, and customers are really realising that now.”

A recent addition to the German brand’s line-up is the BSF 36-4 16H, a pump with a 36m boom length.

Other boom lengths popular in the range are 42m, 49m and 56m.

Meanwhile, Italian concrete equipment-maker CIFA has also been faring well in the region, with double-digit growth in recent years all over the Middle East, says Adalberto Marcello, head of Communication, Digital Marketing & CRM at CIFA. CIFA supplies truck-mounted pumps in its Steeltech and Carbotech ranges in the region.

Pumps in the Steeltech range have booms made of steel, as the name suggests, whereas those in the Carbotech range are made of carbon fibre, which is designed to be lighter and longer-lasting.

In the Middle East, the Steeltech models with boom lengths of 42m and above are the most popular, Marcello says.

While the Carbotech range is also available, it is currently more popular in Europe, which has stricter limits on the loads trucks are allowed to carry.

As the market for truckmounted pumps continues to grow, in parallel with the surge in construction activity, BPME asked: What are customers in the region looking for when buying these machines?

Marcello and Bawidamann both firmly emphasise the importance of product reliability and support from the dealer and manufacturer.

“Customers look for a solid partner to be able to assist them in everyday needs. They expect us to be reactive, responsive to their needs and queries, especially when it comes to spare parts and service,” CIFA’s Marcello says.

Bawidamann points out that ease of use and maintenance is essential. “They need machines which are easy to handle for Concrete Report 2016 23

Concrete Pumps

operators, user-friendly and reliable. The resale value is also quite important.”

Premium equipment manufacturers often admit that Middle East customers tend to be highly purchase price-conscious, which means it can be a challenge to convince them to buy premium equipment and original spare parts, rather than cheaper alternatives.

Bawidamann points out that since a concrete pump is one of the highest investments for a ready-mix business, buying reliable equipment is crucial. “If this machine stops, the whole factory stops. The batching plant has to stop, the drums and mixers have to stop. So this is the most important machine in the ready-mix plant. That’s why reliability is so important.”

A rugged and reliable product is even more crucial in order to withstand operating conditions in the Middle East, notorious for being among the toughest in the world.

“What you have to consider is that the Middle East market is very different from Europe. First of all, you have the climate. You

24 Concrete Report 2016

ThE MixEr goEs hybrid As part of efforts to reduce its

operations in the plant and

environmental footprint, CIFA

when discharging at the work-

has unveiled a new product in

site, the truck’s diesel engine

its concrete mixer line-up: the

can be turned off, and the drum

plug-in hybrid truck mixer from

can be powered by the electric

its Energya series. It is available

motor connected to the battery.

in two models, E8 and E9, and is

During transport, the

much quieter than a traditional

diesel engine recharges the

mixer, while also using up to

electric battery if necessary,

30% less fuel, Marcello says.

ensuring that the truck mixer

In a conventional truck mixer,

can operate autonomously.

drum movement is generated by

“When you brake with a

a hydraulic system. In the hybrid

standard truck, you just lose

mixer, on the other hand, the

the kinetic power that you have

drum is rotated by an electric

when travelling,” Marcello says.

induction motor powered

“With Energya, you’re able to

by a lithium-ion battery.

put part of that energy inside

The batteries can be charged

the batteries to be used later

either from the power grid or

in making the drum turn. So

through a generator powered

it adds a lot of efficiency.”

by a diesel engine on the truck.

The advantage of the mixer

This allows the truck mixer

being able to operate even

to be fully operational even

when the engine is switched

when the batteries are dead

off particularly comes into play

or the truck is switched off.

when noise is an issue, such as

Thus, during loading

in city centres, Marcello adds.

have lots of dust, humidity and heat, which is not good for any machinery. Second, you have a different level of skills in the people who are operating the machines.

An operator from Europe will treat his machine like his baby. Here, people don’t care as much,” he says.

“Third is that the projects are on a much bigger scale than in Europe. The amount of concrete which is pumped here per year is maybe the highest in the world.

So the pumps are running the longest, they are pumping the most, they have the most [unskilled] operators and the worst weather.”

It’s certainly a long list of demands and challenges for equipment to face, so it’s worth examining how manufacturers are adapting to the demands of the region. One way to do this, of course, is through launching new features and systems geared towards making concrete pumps more user-friendly and efficient.

In response to customer feedback on its products, Putzmeister has been working on ease of maintenance on its concrete pumps, Bawidamann says. One approach is to rely more on bolt connections rather than welding on newer machines, making it easier to carry out repairs.

“In the past, for example, the pipe-holders were welded. We have a lot of movement during operations, so the pipe-holders crack and then people start to weld by themselves, which they should not do because it’s special steel.

You need a certified welder, and if [customers] weld by themselves, most of the time they make it much worse. To avoid this, we introduced more bolt connections. Anybody can open and close a bolt, so it’s simpler. We also have much more interchangeable parts, and we have reduced the variety of parts,” he notes, adding that this also makes maintenance a lot easier.

Putzmeister also offers a

Concrete Pumps

Constant innovation Concrete pump makers are constantly innovating their products to enable them to reach greater heights and get faster flow.

“If this machine stops, the whole factory stops. The batching plant has to stop, the drums and mixers have to stop. So this is the most important machine in the ready-mix plant. That’s why reliability is so important” one-sided support (OSS) feature when space is at a premium, allowing the truck-mounted pump to function when its support legs are extended only on one side, so that the boom can still function in confined spaces.

To ensure that the human element, namely the operator, is also accounted for, Putzmeister holds annual training sessions for safety, trouble shooting, technology special projects and so on, to keep operators and technical staff fully aware of how the machines should be operated and maintained.

Technological advances play an increasing role in making concrete pumps safer and more efficient, and CIFA has introduced a Smartronic system, available as an option on the Steeltech series.

Smartronic is an electronic system overseeing safety aspects of the pump to prevent operator error, Marcello explains. For instance, the system can prevent the truck-mounted pump from tilting if stabilisation is incomplete.

Additionally, the system is also capable of recording data, working hours and so on, providing

a convenient interface between the machine, operator and service team. The Smartronic system enables the operator to detect and fix errors as they arise.

However, as tech-savvy as they may be, Middle East customers are not always at the forefront of embracing technology in machinery. Marcello admits that CIFA’s clientele in the region often prefer machines with fewer electronics, which could mean a reduced likelihood of things going wrong. However, the company is actively looking to promote the

system, and clients are beginning to recognise its advantages, which include fuel efficiency.

“The machine is completely managed by an electronic system, one of the main tasks of which is to adapt torque delivery from the truck engine. So it helps to adapt the correct pumping speed and truck engine revolution in order to be more efficient in fuel consumption. In our previous machines, people could have very high RPMs or very low RPMs. Both conditions are not optimal for fuel consumption.”

Concrete Report 2016 25

Automation

relying on precast concrete With the announcement that 25% of Dubai’s buildings would be based on 3D printed technology by 2030, there will be an increasing reliance on precast concrete.

Middle east’s General ContraCtors FaCed with BiG BiM ChallenGe Steel and concrete automation present major opportunity for saving time and money, says Paul Wallett, regional director of Trimble Solutions Middle East 26 Concrete Report 2016

When the Dubai government recently announced that 25% of buildings in Dubai would be based on 3D printed technology by 2030, it sent shock waves down the UAE and Middle East’s steel fabrication and concrete specialists, and general contractors.

Deploying this number of 3D printed buildings will heavily rely on precast concrete – with many of the region’s general contractors not prepared from the technology side for the virtual models and level of automation needed for accurate and efficient steel and concrete.

Specialised steel fabricators and precast concrete contractors across the Middle East are well-attuned to using Building Information Modelling (BIM) software for accurate models shared across the entire

architecture, engineering and construction ecosystem.

For example, Gulf Precast used BIM for modelling and design of the Abu Dhabi Midfield Terminal’s precast concrete piers supporting roadways and a monorail. Also in the UAE, a guesthouse in Ruwais was recently built using a modular design with precast concrete.

But many Middle East general contractors lag behind, with the availability of low-cost labour maintaining business as usual. General contractors tend to estimate steel and concrete amounts when placing bids, leading to costly over-runs and delays on project completion.

Using BIM, contractors can integrate their whole precast and rebar production through automation, leading to increased productivity and enhanced

Automation

helping with coordination BIM can be used to coordinate between engineering, precast and rebar fabrication.

information transfer. BIM helps prevent errors before they happen on the job, and keep projects on schedule and on budget.

Global Best Practices in Concrete Automation

With a slew of stadiums being built in Qatar for the 2022 World Cup, concrete contractors can localise best practices from Clark Pacific, which recently used BIM for concrete automation on the San Francisco 49ers’ new Levi’s Stadium for American football.

By using BIM, Clark Pacific coordinated between engineering, precast and rebar fabrication, procurement and project management. This strategy resulted in a better stadium, which was built quickly, with less impact to the site and reduced lifecycle costs for the owners.

“With the GCC having one of the world’s highest technology penetration rates, the region’s contractors are primed to dive into the mixed reality field”

With standard profiles, shapes and parts, BIM allows contractors to build constructible models that contain accurate data – enhancing speed, accuracy and competitiveness.

For example, Markuciai, Lithuania’s largest manufacturer of prefabricated reinforced concrete products, uses BIM to solve 95% of issues before the element is delivered to the site. BIM in fabrication is vital, streamlining the process of purchasing material, planning production, getting data for mesh and rebar bending machines, and planning logistics.

This was especially vital on the recent construction of the Arkens Väg apartment complex, which saw elements produced in Lithuania and then delivered over the sea and erected in Sweden. The model’s object status data was always available to monitor and coordinate progress and scheduling, with a standardised and easy-tounderstand colour-coding system.

One of the biggest opportunities in the Middle East is for developing fullyintegrated precast concrete production. In Thailand, CPanel Company Limited is Asia’s first fully automated and integrated precast concrete factory. By using BIM software, CPanel drove 90% gains in efficiency and 60% savings in total construction time.

By adopting BIM, Middle East firms can also win business with accurate bids. First, firms often create a massing model of the project, broken into its precast components. Reports are fed directly into spreadsheets, which then guide pre-production and field planning – allowing firms to show advantages over competitors, and providing solutions that meet clients’ needs.

Engineering Heavyweights Drive BIM Innovation

Supporting contractors to save time and costs and reduce inefficiency over suppliers, BIM heavyweights Trimble and Autodesk have recently teamed up for interoperability and open industry standards, exchanging application programming interfaces and developer tools.

These open standards provide all of the needs for the Middle East’s general contractors, which can share models made in open platforms such as Tekla Structures, Tekla Structural Designer or Tekla Warehouse across IFC, DWC or DGN formats, and on open BIM viewers such as Tekla BIMsight.

Driving enhanced levels of construction automation, Trimble’s partnerships with Elematic, Schnell Group and Unitechnik transfer the building information models through electronic data interchange to bending machines, which prepare the rebar for cages and mesh panels.

On formwork, Middle East contractors increasingly use 3D components by PERI to plan and pour concrete with greater accuracy, visualisation, coordination and communication.

With the GCC having one of the world’s highest technology penetration rates, the region’s contractors are primed to dive into the mixed reality field.

For example, AECOM recently announced that it will deploy Microsoft HoloLens in several global pilot projects. With Microsoft HoloLens, engineers can review Trimble BIM designs using 3D headsets.

Dubai’s 3D printed building mandate presents a major challenge to general contractors. By following the lead of general contractors in North America and Europe, general contractors in the Middle East can save time and money, and stay ahead of the innovation curve.

Concrete Report 2016 27

Concrete Equipment

GettinG value for your money

Romieo Amarose, general manager of Express Heavy Equipment Trading and Leasing, outlines the plan for its new range of MAZ concrete mixers in a challenging marketplace meeting requirements MAZ‘s 9-12cbm concrete mixers are tailored to meet the demands of the UAE market.

28 Concrete Report 2016

For current and upcoming construction projects in the UAE market within the next five to seven years, the supply and demand of heavy construction vehicles such as concrete mixers, dumper and tipper trucks has to be equalised with the introduction of more economical and mid-price products.

The products are not to be very highly priced or with less quality for cheaper price levels.

Concrete Equipment

In order to meet the current requirements of performance satisfying and economically priced rigid heavy commercial vehicles, the MAZ brand was introduced in the UAE market

by Express Heavy Equipment Trading & Leasing as its sole agent in 2015’s third quarter.

MAZ is one of the largest heavy-duty truck manufacturers in Europe. MAZ Trucks, founded

in 1944, has a long history in the heavy-duty truck sector.

The product range of MAZ trucks ranges from tractor head units (6x4 & 4x2) and rigid chassis (6x4, 4x4, 6x6 & 8x4) to concrete mixers, suitable for different usage in construction projects.

MAZ has introduced its range of 9-12cbm concrete mixers which are much more suitable for the demand in the UAE market.

The Express group has been a well-known name in the UAE market for good trade quality and good aftersales support for clients. The group has a professional team in order to achieve the vision and mission of the company.

With a wide range of products such as air compressors, generators and now with MAZ heavy commercial vehicles,

they have met all the common requirements and demands of any construction company in the UAE market. With spare parts, stock yard, vehicle workshop of 100,000sqf in Dubai investments Park (DIP) and a set of eight mobile workshops, a client-satisfying performance is being achieved by Express company all over the UAE for present and for future clients.

Express group has its own unique sales strategy and marketing schemes for the promotion of the MAZ concrete mixers and to achieve its target of 100 to 150 trucks per year by 2017.

In order to achieve the market share in the heavy commercial vehicles sector, management has even made plans for the further expansion of showrooms and backup workshops all over the UAE.

MAZ ConCrEtE MixEr trUCks rAngE FroM 7 to 14CbM: Concrete mixer truckMAZ-630303 (6×4)-7m3 (cbm)-250Hp-EURO 2 Concrete mixer truckMAZ-551605 (6×4)-8 & 9m3 (cbm)-330Hp-EURO 2 Concrete mixer truckMAZ-651608 (8×4)-10m3 (cbm)-400Hp-EURO 2 Concrete mixer truckMAZ-650118 (6×4)-14.4m3 (cbm)-435Hp-EURO 3 (Mercedes Engine+ZF Gear Box (16s)

Concrete Report 2016 29

Event Preview

InternatIonal ConCrete teChnology Forum 2016 Held in Dubai and Doha in November, the International Concrete Technology Forum 2016 will bring together experts from across the globe to share knowledge and insight with the regional concrete industry Concrete is a man-made building material and the world’s most used construction material due to its versatility, durability and economy. Concrete is unique among the major construction materials, since it is designed specifically for a particular project where locally available materials are mostly used.

The GCC region’s current infrastructure boom is resulting in several mega construction projects designed with stringent specifications in order to achieve longer service life. Therefore, implementing the latest technologies and practices in the concrete industry is inevitable.

National Ready Mixed Concrete Association (NRMCA), a US-based organisation, and Grey Matters, an innovative professional entity based in the UAE, are organising the seventh International Concrete Technology Forum (ICTF), which will feature the latest advances, technical knowledge, recent regulatory changes and future trends in concrete technology.

30 Concrete Report 2016

The conference will take place in the Grand Hyatt Hotel in Doha on 20 November, and in the Al Bustan Rotana Hotel in Dubai on 22 and 23 November.

This year, Dubai Municipality is the strategic partner of the conference in Dubai, with reference to projects and research initiated with Grey Matters and NRMCA. The ACI Kuwait Chapter, Iberoamerican Federation for Ready Mixed Concrete and Concrete Sustainability Council are endorsing both conferences.

Local, regional and international speakers will share topics like performancebased specifications in practice, sustainability initiatives, the latest innovations in concrete technology and precast concrete. The ICTF Dubai will feature a half-day demonstration during which the delegates will visit a ready-mix plant and watch a new product being used with fresh concrete.

Moreover, the ICTF Dubai will include a panel discussion deliberating the local requirements of Dubai Municipality for Green Concrete – implementation, alternatives and concerns arising from different parties – and will share the results of the Dubai Municipality EPD (Environmental Product Declaration) research introduced during last year’s conference and conducted in partnership with NRMCA and Grey Matters.

Dubai Municipality, NRMCA and Grey Matters will gladly introduce for the first time the Dubai Municipality Awards for ready-mix concrete and precast companies in Dubai.

Companies will be rewarded for several achievements summarised by ten awards, with four specifically for readymix concrete companies and the remaining six awards for ready-mix concrete and precast companies (three levels of awards for each), evaluating

performance in achieving Dubai Central Laboratory certification under Dubai Municipality Standard Specification DMS 026.

The seventh International Concrete Technology Forum will provide learning and networking opportunities, with attendees receiving up to 12 professional development hours (PDHs).

During both conferences, the third batch of NRMCA Certified Concrete Professionals Middle East (CCPfME) will graduate.

The ICTFs are designed to provide learning and networking opportunities for the latest advances, technical knowledge, continuing research, tools and solutions for sustainable concrete manufacturing, design and construction.

Researchers, authorities, academics, students, engineers, architects, contractors, concrete producers, public works officials, material suppliers and concrete industry professionals are invited to attend the ICTF and be part of this networking platform.

concrete@saudidiesel.com.sa

Concrete Technology

Flexible high perFormance

Liebherr showcases its latest concrete mixing plant, the Mobilmix 2.5, and the 50 M5 XXT, its new truck-mounted concrete pump, following their launch at Bauma 2016

higher performance The new Mobilmix 2.5 by Liebherr offers even higher performance than its predecessor and a number of optimisations offer customers even more efficiency.

32 Concrete Report 2016

Launched at Bauma 2016, Liebherr’s new concrete mixing plant, the Mobilmix 2.5, offers clients especially flexible operation due to its easy transport and quick set-up time.

The entire unit can be ready for operation within two days.

Designed to be advantageous for operating at sites with a limited concrete production time, or with other challenging aspects, the Mobilmix 2.5 comes equipped

Concrete Technology

with a state-of-the-art twin shaft mixer, and is comparable to a stationary mixing plant with regard to performance and comfort, Liebherr says.

Compared to its predecessor, the Mobilmix 2.25, the new unit’s output capacity has been increased by 10m3 to 110m3 per hour. The German manufacturer adds that it has optimised a few details, with customers now able to expect increased efficiency,

shorter cleaning times, lower wear and quick assembly times, including for covered plants.

The basic concept upon which the new plant is built has been proven over the last 18 years, across all continents and in varied applications. There are over 300 plants of the previous generation across the world, Liebherr adds.

One of the new Mobilmix 2.5 features is a lowered mixer platform. The slight slope to

115m³/h Theoretical discharge output in compacted mixed concrete

the discharge hopper simplifies cleaning significantly, as do the improved spatial conditions and accessibility to the mixer system.

A new keyless security system on the mixer access hatch eases access for cleaning work. An innovative feed flap on the skip as well as dust filter systems provide maximum dust protection around the mixer platform.

The special design of the skip with parallel designed running surfaces and plastic rollers on the skip ensures comfortable operation with minimum wear and tear. Galvanised assemblies and quality components improve durability.

More or less all building projects, such as tunnels, motorways and airport construction, require a mobile mixing plant these days. Additionally, ready mix concrete companies also require mobile mixing plants to react to changing market demands in a timely manner. The quick assembly and ease of transporting the Mobilmix 2.5 to different sites predestines this plant for such tasks, the manufacturer adds.

Set up in only two days

The Mobilmix 2.5 plant and in-line silo can be assembled and the electric connected in one day. The basic elements of the new Liebherr mixing plant are positioned on a supporting platform which is transported as a whole on a flatbed truck.

The container with the control system is also integrated in this module. The base unit with the mixer system, weighing system and skip is lifted with a crane and unfolded and bolted in working position.

The control container offers generous spatial conditions and is equipped with the modern Litronic-MPS microprocessor

“Compared to its predecessor, the Mobilmix 2.25, the new unit’s output capacity has been increased by 10m3 to 110m3 per hour.

The Swiss manufacturer adds that it has optimised a few details, with customers now able to expect increased efficiency, shorter cleaning times, lower wear and quick assembly times, including for covered plants”

Concrete Report 2016 33

Concrete Technology

control system by Liebherr. Two additional transportation units provide the in-line silo and the support unit with dosing valves and weighing belt. Up to 140m³ of aggregates can be stored in four or six chambers in the in-line silo.

The 3.50m chamber width eases feeding with a wheeled loader.

On the second day, the cement silos are set up and electrically connected. A maximum of six cement silos can be set up, each with up to 120t capacity.

reworked generation The new generation of Liebherr twin shaft mixers has been completely reworked, with the Mobilmix using the new DW 2.5.

New twin shaft mixer

The new generation of Liebherr twin shaft mixers has been completely reworked. The Mobilmix uses the new DW 2.5. Many innovations have been integrated into the series for higher customer efficiency.

All functional assemblies, like electric motors, gears, hydraulics, mixer gate, central lubrication and high pressure

210m³ Max aggregate storage capacity in-line silo

34 Concrete Report 2016

cleaning systems, are placed close together for easy overview.

For service work on the mixer, only one of the four sides requires access. Hose and cable paths have been shortened significantly and simplified. The reduction of hoses, corners and edges reduces the cleaning effort.

The gears are equipped

with a directed oil rinse to stressed bearing points and a radiator which additionally forces air from the fan blades into the belt pulley, for high operating safety even in very hot countries. Changing the wear tiles is also even easier, as all screws are now accessible directly from the outside.

“One of the new Mobilmix 2.5 features is a lowered mixer platform.

The slight slope to the discharge hopper simplifies cleaning significantly, as do the improved spatial conditions and accessibility to the mixer system”

Concrete Technology

A puMp for ALL SiTuATioNS Liebherr also launched its new 50 M5 XXT truckmounted concrete pump to the general public at Bauma 2016. The vehicle, positioned in the 50m class, includes a number of new features and developments, with particular focus on optimising the unladen weight and dimensions.

With the addition of the 50 M5 XXT to the stable, Liebherr now has a range of truck-mounted concrete pumps that cover a variety of uses and situations.

“The boom with five-way multi-folding is extremely easy to operate with its perfect kinematics, while the alternating pipework close to the boom ensures uniform movements over the construction site,” Liebherr added in a statement. “With a vertical reach of 49.1m and a horizontal reach of 44.4m, the compactly constructed truck-mounted concrete pump provides impressive working ranges.”

Another highlight is the newly developed boom pedestal.

Despite considerable weight reduction, the stability has been increased even further.

A crucial role is played here by the proprietary components, such as the slewing ring and the slewing drive. The truckmounted concrete pump benefits from decades of Liebherr know-how in the development and manufacture of these components for other construction machinery.

Optionally offered with four different pump units, the 50 M5 XXT is able to achieve outputs of 138m³ to 167m³ per

hour. Two of these variants are long-stroke versions with a conveyance stroke of 2,400mm, which are particularly smooth and efficient. compact construction, low unladen weight Depending on the chassis, the

total length of the new Liebherr truck-mounted concrete pump is around 12m in the transport position. The new boom is particularly compact and has virtually no projection.

This guarantees safe driving properties and good handling on the construction site.

better cost efficiency The new truck-mounted concrete pump by Liebherr provides better cost efficiency and many innovations for increased customer benefits.

In Europe, the Liebherr 50 M5 XXT is mounted on standard five-axle chassis (10x4). The unladen weight is significantly below 40t, with sufficient spare weight for comprehensive accessories.

For markets without an axle weight restriction, the pump can also be mounted on a four-axle chassis (8x4). In this variant, the unladen weight is below 38t. innovative xxT outrigger system Liebherr is the only manufacturer to supply the patented XXT narrow support, which is extremely stable and warp-resistant.

Front and rear support arms are affixed directly to the distributor boom pedestal, which directs the forces from the boom into the supports directly without deviations.

All four support arms are pivotable. This enables high flexibility and an extremely wide working range for distributor booms on narrow supports. This is of particular benefit on construction sites with limited access.

Chassis from different manufacturers can be used for Liebherr’s truck-mounted concrete pumps. There is a wide range of optional accessories and equipment for the 50 M5 XXT. Customers can choose additional storage compartments, a modular water tank or additional steps on the left side. A high-pressure cleaner makes cleaning easier, and a pneumatic hose end pinch valve prevents concrete running when changing over the boom.

Concrete Report 2016 35

Last word

A global commitment to sustainability Tarana Daroogar, technical services director at Mapei, explains the chemical company’s substantial contribution to the green building sector The increasingly widespread implementation of protocols for ecosustainable design and construction, such as LEED and BREEAM, has led architects and contractors to have a continuously growing interest in ecosustainable products.

But how does a chemical company that manufactures products for the building industry remain sustainable? And how can chemical products be considered eco-sustainable?

Mapei has been working with commitment and conviction in this direction for years, by adopting the three mainstays of sustainability (environmental, economic and social), and for more than thirty years investing in projects for its research laboratories to develop eco-sustainable products.

Products with very low emission of volatile organic compounds

Mapei has developed

36 Concrete Report 2016

solvent-free products with low VOC emissions, which guarantee a good indoor air quality where they are applied, for the wellbeing of both applicators and end users. These products, tested and certified by qualified international institutes, are certified and labelled according to Emicode standards (EC1 and EC1 PLUS) issued

by GEV (Gemeinschaft Emissionskontrollierte Verlegewerkstoffe, Klebstoffe und Bauprodukte), a German association which monitors the emission levels of building materials, of which MAPEI has been a member since 2005.

Some products are also certified Blauer Engel: this label guarantees the quality of the air for both applicators and end users.

GEV and Blauer Engel are extremely severe classification systems that assess VOC emissions from products used in the building industry on

both a short-term basis (three days) and a longterm basis (28 days) from when they are applied.

Both labels consider products to be low emission on the basis of their total VOC (the sum of all volatile organic compounds emitted within a certain period of time after being applied) and the absence of emissions of carcinogenic compounds – benzene, acetaldehyde, formaldehyde, etc.

Mapei products also carry other voluntary, certified labels that guarantee ecosustainability, in order to meet the requirements of local markets, as well as the mandatory labels currently required by law in Germany, France and Belgium.

Carbon footprint and carbon offsetting

The carbon footprint measures the contribution of human activity to the greenhouse effect.

Expressed as tonnes of carbon dioxide equivalent

(CO2e), the carbon footprint identifies and quantifies the consumption of raw materials and energy in the phases within the lifecycle of a product or process to which the emission of greenhouse gases is normally attributed.

Mapei uses the lifecycle assessment (LCA) approach to calculating carbon footprint. This method evaluates the energy and environmental inputs of a product throughout its entire lifecycle, ‘cradle to grave’ – from the extraction of the raw materials used to make the product right up to disposal of any waste products, taking into account all the phases along the way, such as production processes, distribution and final use.

It has been scientifically proven that global warming is responsible for the climate change that has taken place all around the world, and which can be clearly seen by everyone; the emission of greenhouse

gases, first and foremost CO2, is the cause.

Every action that burns up organic substances, from our own breathing to transport, heating our homes and industrial processes, gives off CO2.

This phenomenon has an impact on a planetary scale because emissions, wherever they are produced, mix together in the atmosphere to form an even layer that insulates our planet and prevents heat escaping into space.

It is impossible to completely eliminate CO2 emissions from most production processes, but it is not impossible to eliminate the effect they have on climate change, by compensating local residual emissions which cannot be eliminated technically, through greenhouse gas reduction projects in other parts of the world.

And by adopting this measure, companies play their part in limiting climate change.

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