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Reaching Great Heights Under Extreme Conditions

Photo by Pumpaction Inc. - The Putzmeister 38Z-Meter Truck-Mounted Concrete Boom Pump on site is equipped with the optional SBU conversion kit, making it capable of pumping up to 1885 psi.

Photo by Pumpaction Inc.- The detachable placing boom from the truck-mounted concrete pump was removed and installed on the pedestal at the top of the pin connect tower.

Photo by Pumpaction Inc.- The extended reach of the 38Z-Meter’s boom allowed access to all corners of the job site.

Photo by Pumpaction Inc.- The 38Z-Meter’s detachable boom option allows for greater flexibility on job sites.

Reaching Great Heights Under Extreme Conditions

Putzmeister boom pump helps build 28-floor mixed-use facility

STURTEVANT, WI (Jan. 23, 2012) – When its expansion is complete, Complexe Jules-Dallaire, owned by Cominar Real Estate Investment Trust and located in Quebec City, Canada, will be one of the tallest buildings in the city. To help Phase Two of the project reach its great height – 29 floors – under challenging conditions, the construction team employed a Putzmeister detach truck-mounted concrete boom pump and other Putzmeister equipment, marking the first time a concrete pump and placing boom was used on a high rise building in Quebec City.

Phase One of Complexe Jules-Dallaire, which was completed in 2010, included the construction of two towers joined by a central section. One tower was built up to 17 floors, the maximum height allowed by the city of Quebec at that time, while the second tower had not yet been started. The scope of the $80 million Phase Two of the project, which began in September 2011, consists of adding the second tower to the structure, which when completed will reach 29 floors.

Frédéric Gauthier, engineer and project manager with the project’s general contractor, Dalcon Inc., enlisted the expertise of the local Putzmeister distributor, Pumpaction Inc. and its sales representative, Keith Armishaw, to help him choose the proper equipment needed to deliver the more than 19,600 cubic yards (14,985m3) of concrete required to reach the maximum height of 361 feet (110 meters) for this project. They decided upon Putzmeister’s 38Z-Meter Truck-Mounted Concrete Boom Pump with Series II detach system to place the concrete for the expansion, which is scheduled for completion in late 2013.

Achieving Grand Altitudes
Providing enough pressure to place concrete at a height of 361 feet can be a challenge if the proper equipment is not used. To help overcome that challenge, the construction team is using Putzmeister’s 38Z-Meter Truck-Mounted Concrete Boom Pump, which is equipped with the optional Series II detachable boom and SBU conversion kit, as well as a high pressure hopper and outlet to handle the higher pressure.

“We chose these options for this particular project because the calculated pressure required by the end of the job would be greater than the standard 1233 psi (85 Bar) pressure of the Putzmeister 16 cell pump system,” says Armishaw. “The SBU conversion was used to quickly convert the pump from rod side to piston side oil supply.”

In addition to pressure at that height being a challenge, managing the pouring schedule on a high-rise project can also be difficult. For this job, each elevated floor slab is being placed in two parts. Once the first half of each floor is ready for concrete, approximately 273 cubic yards (250m3) are poured for that section of the floor. Then, columns are poured, along with the second half of the floor. The process of pouring the entire floor level takes from one to two weeks, with weather being a factor in the planning and pouring schedule.

Weathering the Storms
Receiving more than 10 feet (three meters) of snow annually, Quebec City provides a challenging environment for construction in which snow, ice and wind can have a tremendous impact on schedule and equipment. Additionally, contractors need to adhere to strict frost law requirements for tandem axle vehicles, with the maximum allowable weight on the front axle of 53,274 pounds (16,000kg) and a maximum for rear axle of 33,069 pounds (15,500kg) during the thaw period. To accommodate this requirement, the pump is mounted on a twin steer extended chassis, an optional version of the 38Z-Meter.

“Having the option to choose the twin steer chassis was a huge advantage to us in terms of schedule,” says Gauthier. “It allowed us to work throughout the frost thaw period in compliance with regulations.”

Special consideration also needs to be taken to keep the exposed concrete delivery line, which measures approximately 200 feet (61 meters), heated during the winter months, otherwise the concrete could freeze in the pipe resulting in massive schedule delays and significant labor and materials costs. To do this, the contractor is using heat trace wire and is insulating the delivery line. Additionally, insulation is also being used on the boom pipe to prevent it from freezing.

Respecting the Neighbors
Because the existing tower already houses a number of different tenants, extreme care has needed to be taken to minimize disruption during the entire construction process. The pump and placing boom solution was selected for just that reason. This system limits the amount of concrete that would have to be poured using the traditional tower crane and bucket method, which can be messy, cumbersome, and can negatively impact schedule due to high altitude wind speeds. The Putzmeister pumping system allows for cleaner, more efficient concrete placement. Additionally, freeing up the tower crane allows it to be used on other areas of the job, accelerating the production rate of the construction site.

“We have gone to great lengths to minimize disruption to the tenants’ day-to-day operations in the building,” says Gauthier. “The pump is ideal for our use in the restrictive area and particularly for this case, when keeping the tenants and customer’s property safe and clean is a number one priority.”

Also due to the presence of the existing tenants, the pump had to be strategically placed on site. Whereas, traditional concrete placement methods include setting up in multiple locations, moving as close to the placement area as possible, in this case that was not an option due to the amount of obstacles and activity nearby. The solution was to set up the pump in a static location outside of the existing building with the Esser ZX 125 delivery line running through the ground floor and tied into the pin connect tower, which was placed in an opening in the center of the building. Due to the Putzmeister Series II detachable system, the placing boom from the truck-mounted concrete pump was quickly removed and installed on the pedestal at the top of the tower.

“With the long reach of the boom, we had no problem getting to all corners of the construction site,” Gauthier adds. “The placing boom in the middle of the building has been working extremely well.”

Another advantage of the detach boom arrangement is that the boom can be easily be reinstalled on the truck pump and used for more common concrete pumping projects, providing Dalcon with high flexibility when using its Puztmeister equipment on other jobs.

Going for Gold
When the project is complete, the owners of Complexe Jules-Dallaire will seek LEED CS Gold certification (Leadership in Energy and Environmental Design for Core and Shell) in recognition of its sustainable design, engineering and construction. Located in the heart of the city’s economic and commercial center and overlooking the majestic Saint-Lawrence River, the existing tower houses multiple restaurants, banks, and other commercial businesses. The higher floors on the second tower under construction will be home to luxury condominiums, while the lower floors will accommodate additional commercial businesses.

Putzmeister America, Inc. manufactures a complete line of truck-mounted concrete boom pumps, seperate placing booms, truck-mounted telescopic belt conveyors. ready mix trucks and trailer-mounted concrete pumps as well as mortar, grout, shotcrete, plaster and fireproofing pumps and mixers, industrial pumps, tunneling machinary and pipeline systems. Some of the industry's best known brands, such as Tellebelt, Thom-katt, and Tommy Gun are part of the Putzmeister America family. The company's workforce is dedicated to the hands-on customer support and advancing the industry in design and technical innovation.

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General Contractor:
Dalcon Enterprises Inc.—Quebec City, Canada
Ready Mix Producer: Unibeton Ready Mix—Quebec City, Canada
Concrete Equipment Supplier: Pumpaction Inc.—Quebec City, Canada
Concrete Pumping Contractor: Dalcon Enterprises Inc.—Quebec City, Canada
Forming Work: Les Coffrages CCC ltée—Québec city, Canada
Project Owner: Cominar—Québec, Canada
Equipment: One Putzmeister 38Z-Meter truck-mounted concrete boom pump with Series II detachable placing boom; one Putzmeister electric pedestal; three, six-meter Putzmeister pin connect towers; 750 feet (229m) of Esser delivery pipe; one Putzmeister DVH 5/2 hydraulic diversion valve; one Putzmeister hydraulic shut-off valve; and additional piping accessories.