Volume : 2

Issue : 6
Q3 2012

Projects in
Progress

Bridging India with

Schwing Stetter Equipment
See page 5

Notable Projects

Product Focus

10

Technology

Concrete Facts

Do you know that Schwing

Stetter India's Batching Plant
factory is one of the
largest Batching Plants
manufacturing facilities in the
world

MDs Message
The last quarter was one of the most challenging times for the entire construction equipment manufacturing industry. Besides the sluggish
market, the equipment manufacturers had to face further challenges due to increasing trend of exchange rates, stagnant interest costs and
in many States, especially in Tamil Nadu, huge power cuts substantially adding to the cost of the products manufactured.
Schwing Stetter India have taken up all these challenges in their stride and have implemented many projects to stream line their production
facilities, increase efficiencies by cutting down avoidable expenditure and so on. Schwing Stetter India have also used this sluggish time to
train their employees, especially the blue collared workmen on organisational development initiatives focussing mainly on the frontline
warriors. Over 450 workmen are being trained on a specialised tailor made program in vernacular language, titled Inspire & Win.
Schwing Stetter India plans to cover 100% of its workforce in the days to come.
With the help of another training organisation, Schwing Stetter India has also rolled out a program on Quality of Work Life for workmen
and front line engineers together on the same platform and on Quality of Life for newly married workmen along with their spouses. We
strongly believe that these programs are bound to energise them and bring in positive energy in the system.
In the meantime, the recent announcements made by the finance ministry like FDI in multi-branded retail, 49% of FDI in
Aviation Industry and other policy reform initiatives being taken by the government has come as a great relief to the
already sluggish sentiments.
We are sure that the steps taken by the government will go a long way in re-enforcing our confidence on the Indian
Market and the growth of construction and construction equipment industry.
I wish you all and invoke the blessings of the almighty, especially during this festive season starting with Dussera, Eid,
Diwali, Christmas and finally New Year 2013.
All the best,

Kohinoor Square Project

Projects in Progress
Schwing Stetter with L&T team carried out water cleaning system to
avoid the wastage of concrete in pipelines. This method helped to
save concrete and ensure proper cleaning of pipelines for trouble free
operation. With the help of this system an average of 2 m3 of concrete
per pour is being saved. L&T is also using our separate placing boom
SPB35 to achieve fast progress and maximum output. Concreting at
this high-rise project is going on smoothly at 210 meters vertical
height with the joint efforts of Schwing Stetter India and L&T team.

A prestigious commercial project Kohinoor Square is under

construction at Dadar (Mumbai). It is one of the tallest commercial
towers in the city standing 52 storeys high built by L&T ECC.
Schwing Stetter India is involved in building three towers at Kohinoor
Square. L&T approached SSI to plan the concreting method and highrise pumping for achieving the maximum output in concrete
placement. These three towers at Kohinoor Square project are a
mixture of commercial, residential and multilevel car parking floors.

Concrete Pour
An average 4,000 m3 of concrete is
being produced every month for the
past 36 months comprising various
grades of concrete.
Around
1,51,340 m3 of concrete has being
produced till date out of which
Schwing Stetter equipment has
produced 1,37,801 m3. The balance
concrete is procured from ReadyMix Concrete Suppliers.During early
stage of basement and raft
construction, M1 Batching Plant
with BP3500D Concrete Pump
produced 53 m3 of M50 grade
concrete continuously.

EQUIPMENT USED

NO.s

Batching Plant

One M-1 and

One H1.25

Concrete Pump (SP 2800 FGV)

Concrete Pump (SP 1800 HDRC)

Concrete Pump (SP 3500 HDR D)

Transit Mixer

CT News
"Best CEO of India" Awards

Safety Award

Schwing Stetter India recently received "Safety Appreciation Award"

from the National Safety Council (Tamil Nadu Chapter) for the year
2009 with recommendations from Inspector of Factories. The award
was presented by Mr. S.T. Chellapandian, Minister of Labour, Tamil
Nadu.

Mr. Anand Sundaresan, Managing Director of Schwing Stetter India

received award for the Best CEO of India, under Corporate
Excellence Awards, constituted by Stars of the Industry Group,
Mumbai. The award was presented by Mr. Koushik Chatterjee, Group
CFO, Tata Steel and Mr. Arun Arora, Chairman, Edvance Learning
System, honoring his excellence in the industry over the years. The
occasion was graced by other dignitaries and members of the
corporate and press.

Concrete Seminar at IIT

V. G. Sakthikumar is now Co-chairperson,

Mechanisation Committee of BAI
V. G. Sakthikumar, Chief Operating Officer,
Schwing Stetter India has been appointed
Co-chairperson, Mechanisation Committee
for the year 2012-13 by Builders'
Association of India (BAI). In this new role,
Mr. Sakthikumar will act as a catalyst for the
construction industry.

The Indian Concrete Institute (ICI) and Indian Institute of

Technology, Madras (IIT M) organised a two day national seminar on
Modern Equipments for Concrete Construction in IIT- Chennai. In this
unique and specialised gathering, Schwing Stetter India shared its
expertise in equipment for concrete placement and tunnel concreting
which was presented by Mr. John Keenan, Schwing Gmbh. The event
was attended by various professionals, developers, manufacturers
and suppliers to name a few.

7m3 Transit Mixer on Tata Chassis

Schwing Stetter India and
Ta t a M o t o r s j o i n t l y
organised a road-show in
Bhubaneswar to launch
Schwing AM7 Transit Mixer
on Tata Motors LPK 2518
chassis. During this event
Schwing AM7 Transit Mixer
on Tata chassis was
displayed along with
presentation on specifications of the products. The event was
attended by the local RMC companies, hirers and contractors.

Exemplary Leader Award

Another award was bagged by Mr. Anand Sundaresan, Managing

Director, Schwing Stetter India, for Exemplary Leader Award,
constituted by the 3rd Asia's Best Employer Brand Awards 2012. The
award ceremony took place in Singapore and was hosted by the
Employer Branding Institute, World HRD Congress with CMO Asia as
Strategic Partner and endorsed by Asian
Confederation of Businesses.

SSIPL is the only company which can provide total concreting solutions and also provide customised products as per customer requirement
Mr. Mahesh Kanneganti, Managing Director, M/s. KBC Infrastructures Pvt. Ltd.

Notable Projects
Schwing Stetter pump at
Modak Sagar Tunnel

NCC Hydropower Project

Schwing Stetter India has contributed to the successful completion of
NCC (Nagarjuna Construction Company) Shorang 100 MW
hydropower project at, Rampur, Simla (Himachal). The first power
project of NCC has acheived major concreting smoothly with joint
efforts of Schwing Stetter India.

Pratibha Industries in joint venture

with Austria-based STU-STETTIN
Hoch- u. Tiefbau GmbH has done
long-distance pumping at 1180
meters at Modak Sagar site using
Schwing Stetter SP3500HD Pump.
Schwing Stetter India has supplied its
equipment for concreting the Modak
Sagar Tunnel linings. The tunnel is
situated at the west end of the MVP
project area approximately 100 kms
outside the city of Mumbai.

NCC approached SSI for planning the concrete methodology to

complete their hydropower project successful where concreting was
very critical. Schwing Stetter India machines contributed in a major
way by producing concrete of 60000 m3 for the construction of DAM,
HRT, DSB, Surge Shaft, Anchor Blocks, Pressure Shaft and
Powerhouse.

This project involves the construction

of a 7.5 km long tunnel of 4,100 mm
diameter with allied works such as
intake and pipeline for transportation of water. The tunnel is laid
around 90 meters below the ground level, which will have its inlet
close to Modak Sagar dam, and outlets within the same existing
service and bifurcation chamber at Bell Nallah.
Pratibha Industries felt, working with the innovative idea of long
distance pumping was one of the challenging jobs it has faced during
this project. But with the dedicated expert team's support from
Schwing Stetter India, this job was accomplished with great success,
setting a new benchmark.

NCC has used only SSI equipment comprising of two CP18, one CP30
Batching Plant, three SP2800, one SP1800 E, one 350D Concrete
Pump and 18 No.s Transit Mixer for the successful execution of this
power project. The best achievements are 850 meters horizontal
pumping for HRT gantry concrete by SP2800 pump and SP1800E has
done up to 1500 meters further, as relay pumping system.

CP30 Batching Plant at

Dabolim Airport, Goa

Two SP2800 pumps completed twelve anchor blocks of pressure shaft

at the level of 300 meters vertical and 800 meters inclined. Two CP18
plants were erected besides excavated road on the hill, by shifting
through narrow and high gradient roads and these two plants have
produced major concrete for the project.

SP1400 at Universal Infraworld

Our SP1400 Concrete Pump has done 3000 m3 of M25 & M30 grade
concrete at Universal Infraworld, Guwahati. It has pumped 150
meters horizontally and 7 meters vertically. The real estate project
was given to a PMC
( P r o j e c t
Management
Consultancy)
division named
Banka & Associate
for entire technical
supervision.

Construction work of the new integrated international terminal

building of Dabolim Airport at Vasco, Goa is going on in full swing and
about 80 percent of the work has been completed till date. The
project which was awarded to Consolidated Construction Consortium
is expected to get completed by the end of this year.
Consolidated Construction
Consortium has used Schwing
Stetter CP30 Batching Plant to
construct this airport. The plant
has produced 54500 m3 of both
M25 & M30 grade concrete in a
span of 23 months. They have
also used Schwing Stetter
Transit Mixers for easy transportation of concrete to the site.

The project was

awarded to three
different contractors
for construction of
six blocks. Universal
preferred Our
SP1400 concrete
pump for more
output as it can be
used by all the contractors. They are quite happy about the after sales
support being provided by Schwing Stetter India.

The new integrated international terminal building was the need of

the hour considering the fast growth of the air traffic at Dabolim
Airport. The state-of-the-art integrated international terminal
building is being equipped with modern facilities.

Bridging India with Schwing Stetter Equipment

Concreting Solutions

A large numbers of Bridges, Flyovers and Elevated MRTS

Structures are being constructed all over India for better and
faster commuting. They also provide connectivity to different
parts of the city in a country which needs fast transport system.
Most of the bridge structures built in India are being concreted
by equipment of Schwing Stetter India.

Our team of concrete experts look into the depth of the

problems and provide solutions to guide the customer on easy
concreting. Customers call us right away to discuss the project
before the commencement of construction and to find the
possible concrete placing solutions for complicated projects.
Our team provides the best solution which would make the
most sense and would be most cost effective. We have a
complete system approach, helping the customer from the
beginning of the project.

Bridge construction is most complicated because of

unexpected difficulties faced during construction and during
especially concreting. The latest trends and development in
design and technology have lead to many challenges during
the construction of bridges.

Some of the concreting solutions given by Schwing Stetter are;

Selection of equipment for batching, transporting, placing
as per project requirements.

Challenges Faced in Bridge Concreting

The quality and reliability of the concrete is crucial to safe
construction and lifespan of the bridges. To ensure the same,
different ingredients of concrete has to be mixed
homogenously to produce a perfect mix of concrete and has to
be place in short span of time. Bridge concreting is done using
concrete mix up to M80 grade and critical requirements like
casting blocks need maximum strength in minimum possible
time for pre-stressed or post-tension casting.

Use of RVM's for concrete transfer from shore to off shore.

Mounting option for Batching Plant, Transit Mixer, and
Separate Placing Boom on barge and on lattice frame.

Use of minimum space required for setting up our boom

placer which is useful in traffic as well as casting yards.
Pipeline placing and cleaning systems for cast yard,
offshore and high structure application.

Some of the other issues and challenges in concreting of

bridges are stiff consistency concrete producing, placing
concrete girders using cranes (e.g. Metro Projects) along
heavily crowded roads & transportation and laying of concrete
pipes on the sea or river for concrete placement. To overcome
these concreting difficulties Schwing Stetter India not only
manufactures different types of advanced concreting
equipment but also provide various concreting solutions to its
customers.

Equipment Used

Bridge Project by SSI

The most commonly used Schwing Stetter Equipment to place

concrete for bridge projects are: Batching Plants CP30 and M1,
which provide a homogenous mix of concrete. Concrete Pumps
like BP350, SP1800 and BP3500 which are designed with two
valve technologies, Flat Gate Valve (FGV) and Rock Valve,
which enable smooth conveying of concrete to long distances
and also helps to pump stiff mixes for casting.

Schwing Stetter India has contributed in many critical &

landmark bridge projects in India. The different types of bridge
projects where our equipment are used are Beam or Girder
type Bridges (regular), Cable Stayed Bridge like Bandra Worli
Sea Link, Suspension Bridges like Bridge over Ganges in
Kolkata, Elevated Highway Bridge like Pune Kothrud Bypass,
Bangalore Elevated Highway Bridge and Rail bridge for metro &
monorail projects in Chennai, Delhi, Bangalore, Kochi and
Wadala and Vallarapadam Railway Bridges in Kochi.

Transit Mixer 6m3 is usually used to transport concrete for

bridge constructions. These Transit Mixers come with modern
design, simple handling and are cost effective. Separate
Placing Boom- 28meter to 42meter and Boom Placer- 17meter
to 36meter are used for faster completion of concrete
placement. These equipment take on the challenges posted by
the bridge projects.

Schwing Stetter India has also done bridge projects like Hebbal
Flyover at Bangalore, Kosi River Bridge at Assam, White House
Bridge at Navi Mumbai, Delhi
Gate Bridge and Sayan Bridge at
Surat, to name a few.

SSIPL not only provides the high quality service with finest concrete mixing, but also demonstrates commitment to excellence at every turn. Highly Recommended
Mr. Shripad Shikhare, Project Head - Dosti Vihar, Dosti Realty Pvt. Ltd.

Events
BAICON- Chennai

Schwing Stetter's Rock Night

Schwing Stetter India recently organised 'Rock Night' meet for Pump
operators at Kochi-Kerala, Bharuch and Ahmedabad-Gujarat. During
this event SSI covered topics like preventive and periodic
maintenance of rock valve pumps and safety operation tips of
concrete pumps.

Schwing Stetter India recently participated in BAICON-2012 an

International Expo on Construction Equipments held in Chennai. The
event was organised by Builders Association of India Southern
Centre.

As a part of the event small exercise of pump operator competition

was also conducted and based on skills and knowledge, gifts were
distributed. Rock Night provides a platform to the pump operators to
enhance their skills and awareness on safety and maintenance.

National Record in concrete

pouring by Lafarge
On July 24th, 2012, at Chennai, M/s Lafarge A&C India's RMX
Siruseri Plant has set a new record in RMC segment in India by
pouring 1014 m3 of concrete in 24 hours. Schwing Stetter's M1
Batching Plant along with the 13 Transit Mixers and SP 1800
Concrete Pump were engaged, to achieve this.

This exhibition was inaugurated by Mr. K.V Ramalingam, Minister for

Public Works, Govt. of Tamil Nadu. The event was attended by most
of the BAI members, Construction companies and contractors in
Tamil Nadu. Schwing Stetter India showcased its S43 Boom Pump,
7m3 Transit Mixer, CP18 Batching Plant on trailer and SP1400
Concrete Pump which were big attractions.

Schwing Stetter

CP18

This Mega Concrete Pour work was awarded to M/s Lafarge by

SMIPL for their Green Tree Project which was targeted to pour
1700 m3 in 48 hours. Lafarge Siruseri Plant team planned well to
achieve the set target, uninterruptedly delivered and pumped
the concrete for their customer using Schwing Stetter M1
Batching Plant and set a record of 42.25 m3 per hour. M35 Grade
thermocouple concrete was the requirement for Raft Foundation
of the project.

Engineered for Mobility

Lafarge supplied
1014 m3 of concrete
in 24 hours and
completed the total
requirement of 1700
m 3 in 46 hours.
Lafarge team's
efficient planning,
performance of
Stetter equipment
and customer
cooperation at site
were the ultimate for
this success.

The latest innovation of Mobile Batching Plant to

meet the batching requirements comfortably
in remote conditions.

Customer Speaks
Interview with Mr.P.Sampath,
P R Readymix India Pvt. Ltd., Coimbatore.
About P R Concrete
P R Readymix India Private Limited was
started in 1975 by Mr. P. Pappi Reddi and is a
leading provider of ready-mix concrete in
Coimbatore. We stand ahead of our customer
expectation and are one of the ISO Certified
concrete ready-mix providers. We are good in
time management and complete the work as
per the schedule on time. We keep up the
promise to provide better quality with
affordable price.
Our company has a rich history in service, innovation and continuing
growth. We are very happy & proud to introduce our three plants
which are located at Kalapatti, Palladam & Salem running
successfully. With hard work, straight forward, quality and innovative
approach, our team has placed us in the books of many esteemed
customers.

Equipment Used

KTVR Knowledge Park of Engineering &Technology,

Periyamathampalayam, Coimbatore

Our company commissioned

first Schwing Stetter CP30
Batching Plant on March
2001, which is still working
successfully. Currently we
have SSI equipment like
Batching Plants CP30 two
Nos. M1 Batching Plant, Concrete Pumps BP350D, BPL350, SP1400,
BP1800, Transit Mixers 6 m3, 8 m3 and F12 Belt Conveyor.

Ananya Shelters Nana Nani Home, Vadavalli & Thondamathur,

Coimbatore

Why SCHWING Stetter India?

About some of our landmark projects:

We are pleased to say that Schwing Stetter India is one of oldest &
most valuable supplier serving our needs in supplying the materials at
right time. We purchase all our major equipment such as Batching
Plant, Concrete Pumps, Transit Mixers, Conveyor Belts and Spare
Parts from Schwing Stetter. They provide us material with good
quality and they are prompt in service. We would like to appreciate
Schwing Stetter's way of approach. They have also recognised all our
suggestions and our feedbacks are well taken.

Eye Foundation, R.S.Puram, Coimbatore

Sri Ranganathar Polytechnic College, Athipalayam, Coimbatore
Pollachi Institute of Engineering & Technology, Poosaripatty,
Pollachi
We have also supplied concrete for most of the Windmill
foundations in and around Coimbatore

Interview with Mr. Akash Mittal,

Director, Ved builders Pvt. Ltd., New Delhi
About Ved Builders
Our company was started in the year 1994, We
are among one of the top RMC suppliers in our
region. We are also Govt approved contractor
and specialise in DDA projects.

About some of our landmark

projects:
We are currently doing 50,000 m3 DDA road project in Delhi.
Our company is coming up with housing project in greater Noida.
We have constructed 480 EWS flats at Mayor Vihar Phase 3.
We have constructed ICDAR building at institutional area, Vasant
Kunj.
We have constructed additional floor at Kirodimal College.

SSI Equipment Used

Currently we are using M1 Batching Plant with full silo setup, Schwing
Stetter Transit Mixer 10 Nos. and LP1400 concrete pump.

Follow us on

Why Schwing Stetter India?

https://www.facebook.com/schwingstetterindia

We are pleased with Schwing Stetter equipment and their

performance. There are many reasons to select Schwing Stetter
equipment because of their German quality and wide range of
products they offer. We are happy with their sales team because of
their good relationship. We are also happy with after sales support as
they are quick and are highly skilled technically.

https://twitter.com/schwingindia

One Stop Convenience

Mr. Santhosh Rao Balmuri, Managing Director, M/s. Saivani Constructions

Product Focus
3

Nimo 3 m Transit Mixer

TSR 30.14 - Shotcrete Machine

TSR 30.14 is a Universal Shotcrete Machine driven by a diesel engine,
equipped with a shotcrete pump and a telescopic boom for concrete
spraying. The shotcrete pump has the ability to deliver 33 m3/hr of
concrete at 59 bar.
The telescopic boom can be extendable upto 14 meters. The boom
can be rotated to 270 degree about Y-axis. Both the pump and boom
are driven by an electric motor. Emergency operation of boom is
carried out by a separate geared pump driven by vehicle's diesel
engine.
Spraying head consist of three hydraulic motors. Two hydraulic
swivelling motor is for adjusting the nozzle rotation and one hydraulic

Concrete on the go is a key factor today that has helped the RMC
industry evolve. Transit mixers are the most visible among the range
of concreting equipment. But the common 6 m3 class Transit Mixers
are not being allowed to ply inside city roads during the peak hours. It
is because the Transit Mixers are offered on 16 tonner or higher
capacity trucks which is classified as HCVs.
Schwing Stetter's Nimo, a 3 m3 Transit Mixers mounted on a 10 tonner
truck (with 8.25 X 20 tyres) comes under the LCV category. It thus
enables the customer, to drive the transit mixer into the city even
during peak hours and helps to continue the concreting activities
without any delay. Smaller capacity Transit Mixer is also a more
economical option for sites which do not need large Transit Mixer,
specially for contractors.

Features

Power-controlled hydrostatic drive unit with variable pump mounted

directly to the diesel engine. Power to both axles is transmitted by
means of hydrostatic variable motor via transfer case. Steering of
vehicle is switchable to four-wheel steering, front-axle steering and
crab steering.

Nimo comes with shorter truck wheel base of 3250 mm and an overall
height of 3250 mm on fully built vehicle. This helps the customer to
drive the vehicle comfortably through narrow, congested lanes and in
hilly regions as well, where sharp turns are quite normal and
unavoidable.

Open drivers stand equipped with ROPS/FOPS shelter. The vehicle

can be driven in both directions by rotating the stand to 180 degree. It
also has Hydraulically driven water pump of 200 bar for cleaning
purpose.

The unique ability of Nimo, running through all kind of roads and
narrow passages, enables the user to carryout concreting
continuously.

Schwing Stetter S43 Boom Pump

construction site thanks to their low height

that saves space and time. S43 SX outriggers
are designed to be compact, with a fast set-up
time. It requires an 8.3m outrigger spread
(the spread is the same, front and rear) for
maximum stability.

Schwing Stetter redefines standards in the 40 m class with its S43SX

truck-mounted concrete pump. Schwing RZ boom design combines
the Roll and Fold boom with a Z-fold boom at the tip to offer 270
degree flexibility at the last boom section. The boom folding system
also enables concreting work right up to the vehicle bumper. With an
overall length of less than 12 m on a standard chassis this compact
boom package does not extend beyond the machines outlet.

The standard Schwing Remote Control

features twin joysticks for proportional boom
control and pin-point accuracy. In addition,
Schwing's Vector control is the only system
providing two-way communication between
the pump and the operator.

With the 270-degree Z-fold section at the tip of the boom, operators
have a myriad of options for placement while shooting concrete up to
42.3 meters vertically, and 38.1 meters horizontally. The S 43 SX has
an unfolding height of 8.7 meters for those low overhead situations
and a slewing range of 740 degrees to suit many job site
requirements. Its pipeline is a full DN-125 mm diameter.

The Generation 3 concrete pump is a lowmaintenance, 164 m3/hr unit that provides
long, slow-stroking action. The all-hydraulic
design utilises Schwing Big Rock Valve,
promoting maximum filling efficiency of the
material cylinders even with harsh mixes.

The S43 SX front outriggers extend along an arc, do not have to be

swivelled or telescoped and can fit into even the smallest gaps at the

An open circuit design provides continuous

hydraulic oil flow for fuel efficiency, filtration
and cooling. The S 43 SX can do infrastructure
work, light commercial projects and bridges.
In conjunction with the DN-125 pipeline,
contractors can perform high-volume pours
or provide a slow delivery with infinite volume
control. A 600 liters water tank on the unit
helps with clean-up at the yard or on the job
site. Consistently lightweight design makes
this machine a universal and flexible longboom pump - both for medium-sized
operations in downtown urban areas and on
large construction sites.

Project Abroad

Castle Concrete Pumping Builds a Castle

Schwing S 47 SX one among the range of pumps used in this project

It was an interesting project because the owner's wishes changed as

the project evolved, so it was back to the engineers to redesign or
expand a portion. Paul Tingle , an Italian contractor for day-to- day
operations, who oversaw the hundreds of pours performed by Castle
Concrete Pumping, said Rich, Obe and their operators work very
hard to earn and keep the business. Dario set his sights on a dream
and Castle helped deliver the dream. I use their pumping service all
the time for my custom home business.

Schwing S 47 SX at project site

The Castello Di Amorosa is an authentically-styled, 13th century

medieval Tuscan-style castle and a Napa Valley landmark in
California, thanks to the vision of the owner Mr. Dario Sattui and the
dedicated construction crew that saw it through to completion.
Started as a 8,500 sq.ft. project, it grew to its finished size of more
than 121,000 sq.ft. It incorporates medieval construction techniques
that qualifies the structure as a true castle complete with moat,
drawbridge, high walls, towers, a great hall, courtyards, secret
passageways and, of course, a torture chamber.

Of course self-respecting castle would not be complete without a wall

around it. Fortified defensive walls that were designed to be 18inches thick were expanded to three-feet of poured concrete to be
consistent with dimensions of 13th century castles. Most of the
concrete is covered with locally sourced stone attached by mortar and
brackets. More than 8,000 tons of stone were hand-chiseled in
keeping with the owner's desire for authenticity. In olden times when
castles took years to build the stone would often change as
construction progressed and new sources were found. So it is with
Castello Di Amoroso. The exterior appearance takes on a different
look depending on when it was built.

As the project grew, so did Mr. Rich Castle's Castle Concrete Pumping.
"In order to service the project, both longer and smaller booms were
required," explains Mr. Obe Elliott, Pumping Manager for Castle
Concrete Pumping (CCL), We grew to having a large fleet with over a
dozen different sizes of Schwing concrete pumps available, ranging
from 17 to 58-meter boom length and several Schwing line pumps,
including a SP 500, SP 750, SP 1000, and chassis-mount city pumps.
And we used them all at one time or another on this project. CCL
pumps were constantly on call for the project.

Schwing KVM 52 pumps the three-foot thick fortified defensive walls

Castle's pumps handled all of the mixes supplied for the job including
lightweight concrete that was used for upper levels that were not in
the original plan. Foundations that were constructed for fewer
stories, had to accommodate higher loads when additions were
added. Plus this was the first castle built as per Seismic Zone 4
specifications. We kept an eye on the sand in the half-inch
lightweight mixes and kept the specific gravity in line, Mr. Bob Abbot,
General Manager for the Ready-Mix firm explained, The Castle
pumps had no problems. Short six mile hauls kept the temperature of
the mix in spec even on the hottest days. Most loads were 4,000 psi,
6.2 sack blends with 15 percent flyash. We
supplied lots of colored material, according to
Abbot, Mostly mortar but also concrete.

Schwing KVM 39X performs at Castello di Amorosa

The physical dimensions of the site are 250-feet by 600-feet, a large

area that became more cramped as the project outgrew the original
plan. Small boom pumps played a big role in the pumping, explains
Elliott, Our 17, 24, and 25-meter pumps were used extensively for
tight access and low clearance pours, but as the project design grew
and elevations increased, the longer Schwing booms were needed for
deep footings, mat slabs, and tall walls, where the small footprint
provided by their X-style and Super X outriggers paid off.

Because of the Good reliability of Schwing Stetter Equipments and service, they have become best tool in our industry
Mr. Thiyambak Pandey, Assistant General Manager, P&M, WELSPUN India.

Tech
Ascertaining concrete pressure using Nomograph
One of the major requirements of concrete pumping is ascertaining
which pump will be suitable to do a particular job. To identify the right
pump for the right job, we should know exactly what are the variables
which affect the pumping. Since ascertaining the pumping pressure is
most important before we start the pumping operation, a tool to find
out the same can be of immense help.

Nomograph for ascertaining the pumping

pressure
By means of the nomograph the pumping pressure for a delivery
output can be ascertained provided that the horizontal and vertical
placing distances, the consistency, the installed bends and the
pipeline diameter are known. The nomograph is based on values
compiled by SCHWING over more than 15 years on pumping jobs in
Germany and abroad. It has turned out that even under the most
varied site conditions the values recorded on the basis of the
nomograph, i. e. the theoretical ones, and the actual values are in
adequate conformance. The deviations are within a range of 10%. It
can be derived that the pumping pressure to be expected can be
ascertained with accuracy adequate in practice.

Pipeline diameter
In the upper right corner of the nomograph straight radial lines are
assigned to the various nominal diameters of the pipelines (DN 100DN 150). The resistances due to tapered pieces, by means of which
the pipelines are connected to the concrete pumps, have already
been incorporated in the nomograph.

Indicated below are the essential points for ascertaining the pumping
pressure by means of the nomograph.

Proportional value of the pipeline - horizontal

placing distance

3750
3300
2750
2250
1875
1125

Nomograph
Technical identification number

150

The proportional value of the pipeline is to be interpreted as the entire

pipeline laid, where at the flow resistances of the pipe bends are
reckoned among the horizontally laid pipeline. SCHWING recommend
bends with a radius of r = 1 m for all diameters. The proportional
value of a 90 deg. bend with a radius of r =1 m is 3, independent of its
diameter; this means that its flow resistance corresponds to that of a
3 m long horizontal pipe section. Hence it follows that a 30. bend
with a radius of r = 1 m has a proportional value of 1. If for example
bends totalling 540. are installed in a pipeline system, this is
equivalent to a proportional value of 540 /30 =18.

Pipeline dia (mm)

125

70
60
50
40

100

30

150
132
110
90
75
45

20

10

Working Power (Kw)

80
For vertical placing
add 0.25 bar per meter
of level difference

Flow rate in cum / hr

112

10
120 110 100 90

80

70

60

50

40

30

20

Pressure in bar

Vertical distances are added as an extra pressure while ascertaining

the placing pressure. They are not considered in the proportional
pipeline value. The length of the vertical line is included in the total
pipeline.

50
K2

100
60
K3
70

Concrete consistency

200
80
100

120

Slump of fresh concrete (mm)

140

160

600 500

400

The concrete consistencies are indicated as radial lines in the left

lower sector. They have been ascertained by experiment in relation to
the spread measure. The indicated slump is based on empirical
values.

300

Proportional value of pipeline (m)

Please download a high resolution copy of the above nomograph from

http://www.schwingstetterindia.com/Nomograph.pdf

Pumping pressure

Concrete output as a function of the work factor of

a concrete pump

The pumping pressure can be read on the left horizontal coordinate of

the nomograph. No possible pumping height is considered in this
value. The pumping pressure ascertained by means of the
nomograph refers to the pressure at the pumping piston (concrete
piston) of the concrete pump and is not to be confused with the
pressure in the hydraulic system. The pressure in the delivery pipeline
immediately after the reduction pipe depends on the ratio of the taper
up to 15% lower than the pressure at the piston and is decisive for
dimensioning the pipeline.

To determine the pumping pressure with the aid of the nomograph

start from the concrete output plotted on the vertical coordinate. The
velocity of the concrete flows in the pipeline and thus the pumping
pressure depends on the delivery output. Hence it follows that one
must start from the actual output, i. e. the delivery output which
creates the rate of flow.
If a site intends to pour 50 m3/hr, then a concrete pump with a max.
output of 50 m3/hr can achieve this output only by pumping 60
minutes per hour. Such ideal conditions are seldom complied with on
sites. In practice, the work factor of the concrete pump will possibly
be 75% only (i.e. 45 minutes per hour), since the concrete
distribution often requires repositioning of the pipeline or the
approach of truck mixers to the concrete pump is impeded because of
confined space on site. A work factor of 75% means that for a desired
output of 50 m3/hr the concrete pump must place 50 m3 of concrete
within 45 minutes which results in a delivery output of approx. 67
m3/hr.

Determination of pumping pressure with regard to

vertical placing distance
The static pressure resulting from the pumping height is added to the
pumping pressure which has been ascertained by means of the
nomograph. It amounts to approx. 0.25 bars per meter of level
difference. Only the level difference is considered, thus the ascending
gradient of the pipeline whether laid vertically in a building or inclined
on the ground is irrelevant. Thus the final concrete pressure derived
using nomograph can be used for proper planning and use of your
concreting resources. Happy Pumping!

10

Tech
Wall thickness and wear of pipelines
Concrete delivery pipelines are subject to wear. Its extent depends on
the quality of the pipe material, on the flow velocity of the concrete,
on the concrete pressure in the pipeline as well as on the hardness,
shape and mixing ratio of the aggregates. The pressure in a pipeline
system drops from its maximum value at the pressure source towards
the outlet. This means that pipes close to the pump are subjected to
higher wear. Therefore preferably new pipes or pipes with thicker
walls should be used here. For the most part, pipes used for placing
concrete have a wall thickness of 4.5 mm. They are only sufficient for
moderate pressures. A pipe section DN 125 with a wall thickness of
4.5 mm, for example, can only absorb a maximum pressure of 112
bar. The table shows the wall thickness as a function of the pumping.

Pressure with differing pipe diameters

For high and highest pressures of up to 200 bar Schwing offers pipes
with a wall thickness of more than 7 mm. These pipes use flanges for
the Schwing cup type tension couplings. In case the wall thickness
falls short of the minimum requirement, which depends on the
maximum possible pumping pressure of the concrete pump, the pipe
sections particularly those close to the concrete pump must be
replaced. Danger of accidents!!! The wall thickness of pipes can be
easily checked with an ultrasonic measuring unit or by spot-drilling, if
necessary.

Minimum Pipeline Thickness Chart

3000

210

130
1800
1600
1400

m
m
0

0
15

m
m

ID

1. This chart assumes a safety factor of 3:1. Higher safety factors

may be required in some circumstances.
2. Wear reduces wall thickness. Thickness must be checked on a
regular basis.

ID

2000

Note:

PE
PI

5m
m

150
140

12

PE
PI

HE

160
2200

ID

PI
PE

170

m
m

ID

12

CONCRETE PRESSURE BAR

2400

180

10

2600

190

AT
TR
EA
TE
D

2800

PI
PE

200

120

3. Pressure may be limited even more by clamp style or pipe end

used.

110
100
90

1200
1000
800

4. The chart is based on 52,000 PSI tensile strength. Heat treated

calculations are based on a 50 percent increase in tensile
strength.

80
70
60
50

600

40

400

30

5. The chart is for pressure calculations only. There is no allowance

made for mechanical forces due to improper support or restraint.

20
200
0
PSI

6. The chart does not take into account metal fatigue caused by
pressure cycles.

10
0
0

1.27
.635

2.54

1.905

3.81

3.175

5.08

4.445

6.35

5.715

7.62

6.985

8.89

8.255

10.16

9.525

11.43

This chart is intended for concrete pumping applications and is

subject to the notes, assumptions and conditions noted above. Any
other use of this chart is not recommended.

12.7

10.795 12.065

PIPE WALL THICKNESS in mm

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11

Dear Customers,
Greetings!!
In this issue, we have discussed SCHWING Stetter's contribution for Bridge Construction Projects across India. We are proud that our equipment
played vital role aiding Customers to build landmark bridges across the mighty Brahmaputra, Ganga and other rivers in different parts of the
Country.
We are pleased to share with you a report on Construction of a Castle in 13th Century Medieval Style where our Boom Pumps and Trailer
Pumps were extensively used abroad.
This issue briefly covers topics related to Wall Thickness and Wear of Pipelines.
Our machines continue to set records in different segments like for example, at Lafarge where 1014 cubic meter of concrete was poured within 24
hours using our M1 Batching Plant.
We have also brought out an On the Spot Report about the Modak Sagar Tunnel Project and we are glad to
inform that more such reports will follow in the months to come.
Through this issue of Concreting Times, we would like to invite all the members of Builders Association of India to
visit the 40th IFAWPCA Convention scheduled to be held in Kochi from 6th to 9th January 2013, were
SCHWING Stetter is the main sponsor.
With the monsoon season coming to an end, we see increased interest and activity amongst our customers and
hope that this trend grows further and helps the Industry to come out of the current slow phase.
I take this opportunity to thank all our Customers who took advantage of the special offer scheme for our Service
Centers during the Monsoon.
Happy reading!!!
With best regards,

V.G. Sakthi Kumar, COO

sakthikumar.vg@schwingstetterindia.com
For any feedback regarding this newsletter, email at editor.ct@schwingstetterindia.com

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Made in

GERMANY
Schwing Stetter is the pioneer in manufacturing of concreting equipment for the past 78 years. Quality products, strong design
capabilities and the experience from developed countries during its growth phase make Schwing Stetter the preferred choice world over.
Batching Plants I Concrete Pumps I Transit Mixers I Concrete Recycling Plants I Belt Conveyors I Separate Placing Booms I Shotcrete Pumps
ISO 9001:2008 :: OHSAS 18001: 2007 :: ISO 14001:2004
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Phone : 044 2715 6780 / 781, 47108100 / 33555588 Fax : 044 27156539 Visit us at www.schwingstetterindia.com
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Published by Schwing Stetter India in Chennai. All Correspondence to be sent to editor.ct@schwingstetterindia.com
Designed and Printed by A.L. Senthil Kumar :: For private circulation only, not for sale.

Many more to come...

October 2012