Putzmeister Thom-Katt® TK 40 Reaches New Heights at Plaza South
Putzmeister Thom-Katt® TK 40 Reaches New Heights at Plaza SouthQuality Concrete Pumping’s TK 40 overcomes logistical challenges to place concrete for patio restoration
STURTEVANT, WI (July 28, 2008) – Quality Concrete Pumping (Quality) and one of their Putzmeister Thom-Katt® TK 40 trailer-mounted concrete/shotcrete pump’s were ready for the challenge when Commercial Concrete Restoration Services (Commercial Concrete) needed help restoring deteriorating concrete patios for Plaza South, a 29-story condominium in Fort Lauderdale, Florida.
Originally built in 1971, Plaza South comprises three wings of differing heights: 24-story, 29-story and 14-story.
According to Vinny Petrillo, field supervisor for Commercial Concrete, it was determined by Plaza South, that most of the patios were unsafe because of deteriorating concrete.
“Over the course of 37 years, the salt in the air from the Atlantic Ocean caused the rebar in the concrete patios to expand,” says Petrillo. “When rebar expands, the concrete cracks. We’re also seeing this happen to other condominiums along the coast.”
Calling on the Thom-Katt
Petrillo called on George and Jeff White of Quality and their TK 40 to restore the deteriorating concrete patios.
Quality has been in business for 20 years and have an impressive fleet of Putzmeister pumps including: a Katt-Kreter™, a TK 30, five TK 40s, four TK 50s, a vehicle-mounted Thom-Katt VS 70 PTO and a VS 50.
“I’ve worked with George and Jeff in the past,” comments Petrillo. “Their Putzmeister equipment, team and service have been nothing but dependable and reliable. “Because of Plaza South’s small footprint, we needed a compact, yet powerful pump. The application demanded a pump that could deliver concrete up to 300 feet (91m) high, and I knew from my experience with Quality’s TK 40 that Plaza South would be just the job for it.”
According to George White, the highest Quality has ever reached vertically with a TK 40 is 390 feet (119m).
Quality arrived on site in July 2006 to start work on the patio restoration job.
“The reason for the long duration of this project is due to working around the occupants of the condo units and working with Plaza South’s budget constraints,” notes Petrillo.
Because there were sporadic spots on various floors of the three different wings that needed concrete patio restoration, there was not a huge quantity of concrete pumped and placed. Only about 100 to 200 cubic yards (76 - 153 m3) of concrete was needed.
“We really pushed the TK 40 to the limit with this one in regards to the height and because of that we were able to showcase its smooth, reliable pumping even in extreme circumstances,” notes White. “What was even more convenient for this project is that the TK 40 makes for a simple setup and tear down; with three different locations throughout this project for the Thom-Katt, the feature was a huge help and time saver.”
“There were no hiccups whatsoever with the Thom-Katt,” adds Petrillo. “The TK 40 is nothing less than the highest quality machine.”
According to White, the deteriorating concrete was first removed and then new rebar was installed. After the rebar was installed the concrete was placed.
“The concrete mix was a standard 6,000-psi concrete mix with a C1 corrosion inhibitor,” Petrillo explains. “This should help prevent deterioration of the concrete patios in the future.”
En Route to the Top
Quality’s TK 40 was positioned at three different locations for each of the three wings throughout the restoration because of its L-shaped design, according to White.
“For the 24-story wing, the TK 40 was positioned quite a distance away from where it was placing the concrete,” comments White. “This was due to the lack of accessibility on the site to position the Thom-Katt for this wing. The Thom-Katt pumped via slick line up 20 feet (6m) to ground level at the pool deck, then another 200 feet (61m) horizontally across the pool deck, then up the wing 300 feet (91m).
For the 29-story wing the setup was very similar to the 24-story wing except the slick line did not go over the pool deck.
“For the 14-story wing, we had the TK 40 positioned below ground in the parking garage. The slick line from the TK 40 traveled 50 feet (15m) horizontally, then 20 feet (6m) up to the ground level, then another 50 feet (15m) up the wing to the top.”
At one point, according to White, there was an impressive 540 feet (165m) of slick line system in use. The slick line had 10-foot (3m) sections and was two inches (51mm) wide.
“The slick line that went up each of the three wings was secured to the building by a U-bolt,” says White. “We started placing concrete for each wing’s patios at the top and worked our way down. Because not every floor needed restoration, there were times we went down four floors, and the 25-foot (7m) hose we had connected to the end of the slick line to place the concrete wouldn’t be able to reach that far down. So, when we were ready to go to the next floor below, we disconnected the hose from the slick line. Then, when we reached our next floor and we were ready to pump, we unhooked the U-bolt on that section of the slick line and reattached the hose and started placing.”
Pumping concrete 300 feet (92m) high was a main concern on site; however the top concern on site was the hose men’s safety.
“Every precaution was taken due to the combination of the constant high wind gusts from the ocean and being up 300 feet in the air,” says White. “Since the platform the hose men stood on was only two inches (51cm) thick, the hose men were supported by heavy-duty, sturdy harnesses. Safety is always number one.”
Petrillo and his team at Commercial Concrete have not only been managing Plaza South for the patio restoration, but for a variety of other repairs such as water proofing, chemical injection work inside the parking garage and other miscellaneous repairs, since 2004.
The patio restoration was complete in June 2008. That may not be the last time Quality and their
TK 40 will be on site.
“We’re waiting to hear on Phase II, where outside walkways from the elevator to the condos need restoration of concrete because of the salt in the air,” says White. “So this would be a much larger area, but up just as high.”
“If Phase II does go through, we have Quality on speed dial,” comments Petrillo. “We know we can rely on their professionalism and the performance of their equipment.”