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Putzmeister Pump Breaks World Record at Burj Dubai

From left to right: Badri Narayanan, service manager of the Putzmeister agent, German Gulf Enterprises (GEE); Christian Stirm application engineer at Putzmeister; and J.P. Santosh, head of machine technology at Unimix, a sub-contractor of the project; celebrate the new world record.

A Putzmeister MX 32-4 T placing boom placed the concrete at the world record height of 1,971 feet (601m). To improve concrete placement in the tightly packed reinforcement, a flexible plastic nozzle is fitted on the end hose.

View of the Putzmeister pumping station and the pipeline installation.

One of Unimix’s BSA 14000 SHP-D pumps during night-time use on the Burj Dubai.

Once complete, the Burj Dubai will stand an astounding 2,625 feet (800m) tall.

Putzmeister Pump Breaks World Record at Burj Dubai

BSA 14000 SHP-D reaches 1,971 ft. (601m)

STURTEVANT, WI (February 1, 2008) – In early November 2007, a Putzmeister BSA 14000 SHP-D pump reached a concrete conveying height world record for the Burj Dubai – an astounding 1,971 feet (601m). At the record-breaking height, a concrete wall of the central building core was placed by a Putzmeister MX 32-4 T placing boom for level 155.

This world record wasn’t conceived overnight, however, as preparations began in early 2005 for the massive Burj Dubai project in the United Arab Emirates by both Putzmeister Aichtal Works and its local Putzmeister agent, German Gulf Enterprises (GGE).

Once on-site, Unimix (the concrete supplier and pumping service for the project) deployed a carefully designed concrete placing system including two Putzmeister BSA 14000 SHP-D trailer-mounted concrete pumps and one BSA 14000 HP-D trailer-mounted concrete pump; a carefully engineered delivery line system; four non-ballasted stationary placing booms (three MX 28-4 T and one MX 32-4 T placing booms); and various truck-mounted boom pumps.

“We conducted extensive tests with the BSA 14000 HP-D pump and delivery line on-site,” says Christian Stirm, application engineer at Putzmeister’s global headquarters in Aichtal, Germany. “The tests were conducted with horizontally laid pipelines to simulate the pressure behavior and expected friction of the concrete in the pipeline based on concrete mixture breakdowns, as well as converting it to the high-rise pumping.”

Putzmeister was faced with the challenge of creating a new, super high pressure trailer pump, the BSA 14000 SHP-D, specifically for this project. The pump’s frame and hopper were reinforced in order to withstand the enormous forces of the concrete mixtures. Among the other characteristics of the new pump include: adjusted S-Valves and S-Valve bearings for the expected pressures and a high-tech filter system.

The two BSA 14000 SHP-D and the one BSA 14000 HP-D pumps were combined to create one pump station for this project.

Multiple attributes of the Burj Dubai make this project one-of-a-kind:
•Only high compressive strength concrete mixtures are being used on this project.
•Pours are only done at night because of the hot temperatures during the day.
•Concrete is chilled in the concrete plant prior to preparation and part of the water is replaced
with shards of ice, which allows the concrete to be transferred at 82°F (28°C) (night-time temperatures in Dubai usually reach 104°) to the project site.
•Each batch of concrete is monitored and logged in the plant; before transferring the concrete to the pumps, the temperature and flowability are checked regularly; sample cubes of the batches are poured to check pressure.
•Putzmeister engineers developed a unique delivery line system where the line’s wear behavior, its compressive strength and routing throughout the structure was considered.
•The 75,347 ft2 (7,000m2) base plate of the structure was placed by numerous Putzmeister boom pumps. The foundation is supported by 200, 5-ft (1.5m) diameter concrete piles for the core tower and 650 concrete piles for the tower’s wing sections.
•Three of the trailer pump delivery lines were connected to the three MX 28-4 T Putzmeister placing booms, which were secured on platforms of an auto-climbing formwork and stood on 52-foot high (16m) tubular columns for the structure’s wing sections.

At the record-breaking 155 level, a flexible plastic nozzle was fitted on the end hose of the MX 32-4 T to improve concrete placement in the tightly packed reinforcement.

Three of the stationary booms and one of the stationary pumps have now been removed from the site due to the project’s rapid progress in construction and the narrowing building structure as it rises upward. The tip of the Burj Dubai is being erected with steel starting at the 156th level. Only the decks will be placed with concrete up to the 160th level – 2,004 feet (611m) – via horizontally laid pipelines and hoses.

The total height of the three-winged tower located in central Dubai will be an estimated 2,625 feet (800m) tall once topped out, making it the world’s tallest tower, according to The Council on Tall Buildings and Urban Habitat (CTBUH). The tower will comprise approximately 326,988 yd³ (250,000m³) of concrete when complete.

Slated for occupancy in 2008, Burj Dubai’s first 37 levels are being reserved for a hotel; above the hotel floors will be 700 apartments, suites and offices. On the 124th level there will be a panorama platform offering a spectacular view of the 297-acre (120-hectare) site that holds space for 30,000 apartments and the world's largest shopping center – the Dubai Mall.