Layher Allround TG 60 – The Ideal Shoring System

by Sawon Banerjee | Oct 13, 2020 | Construction Equipments

Mithilesh Kumar Director, Layher Scaffolding Systems Pvt Ltd

Layher Group produces high-quality scaffolding systems in Germany. Layher has worldwide presence with more than 30 sales subsidiaries. The products are being used by industries like construction, chemical plants, power plants, as well as at shipyards and offshore.

More Possibilities – Layher Products and Services

Layher’s present product characteristics and services help customers achieve long-term success and increase the profitability of their companies. The Layher Allround Scaffolding has been established as a synonym for modular scaffolds on the market.

Layher Allround Shoring TG 60

The False work frame – even more possibilities in Allround Scaffolding

Construction Of Layher Allround TG 60 “South-East Of Zurich, Switzerland’s

Allround scaffolding uses a simple, unique and bolt free connection technology. Sliding the wedge head over the rosette and inserting the wedge into the opening immediately secures the component, leaving sufficient place to secure the other end of the ledger. A hammer blow to the wedge transforms the loose connection into a superbly strong structurally rigid one. The face of the wedge head is then precisely positioned against the standard.

The new Layher Allround false-work frames have been developed as an extension of the Allround Scaffolding Systems. With three new additional parts, we can assemble false-work towers even faster higher and sturdier. The shoring frames TG 60 are available in three sizes: 1.00 m x 1.09 m, 0.50 x 1.09 m and 0.71 m x 1.09 m. The base frame H = 0.71 m is equipped with Allround rosettes at the top and the bottom and has no spigot.

The false work frames are made of steel tubes of high strength and are stiffened with 2 small diagonal braces. Every vertical standard can be loaded with up to approx. 6 tons. The ends of the welded ledgers and diagonal brace are fattened. This makes the Allround rosette fully useable.

To transfer pulling force, every frame is secured by locking pins or bolts to each other. In this way the tower can be assembled on the ground and placed by crane.

The product innovation is assembled out of the newly developed Allround Shoring Frame TG 60 as well as Allround standard parts like ledgers and diagonal braces. In this way, the advantages are intelligently combined: quick assembly and dismantling, thanks to reduced number of components, light component weight, screwless wedge lock connection technique and optimum material utilisation, as a result of variable bay lengths. These can be adapted flexibly to the existing loads and the grid dimension of the formwork beams. Scaffolding companies increase assembly speed with it due to their day to day experience and moreover offer an attractive full package. They implement requests of the building contractors on-site, without any difficulty with the Allround construction kit – whether they are exact adaptations to difficult building geometries, extensions like production stages and stair towers or supplementary solutions, for example concreting platforms and bracing scaffolding.

Application Of Allround Shoring TG 60

For the greatest possible efficiency in the construction of the 46 metres long and 28 metres wide shoring tower structure, the scaffolding company considered all three construction phases already during the planning: setting up the moulds for the down stand beams, laying and concreting of the semi-finished ceilings as well as creation of the upper floors. In accordance with specifications the scaffolders utilised the material-saving 1.09 metres wide and 1.57 metres long tower versions, which sped up the procedure and simplified logistics. In longitudinal direction, they connected the shoring towers at the head of the tower with two 1.09 metres scaffold bays each and one built-in Allround ledger. With the aid of the system components, elaborate calibration was obsolete: After erecting the shoring tower for the first beam axis, the further assembly resulted from the dimensions of the system components and the automatic rectangularity.

On the one hand the scaffolders adapted the 6.5 metres high shoring tower structure exactly to the grid of the down-stand beams, and on the other hand, created ideal prerequisites for the second and third construction phase. The reconstruction work was therefore reduced to the minimum: As a support for the concreting of the semi-finished ceilings, the shoring tower structure was simply raised to the bottom edge of the semi-finished ceiling by inserting a 2.5 metres high Allround standard onto the Allround standard already integrated in the connecting bays. The loads were absorbed by the intermediate bay and transferred directly into the adjoining shoring towers by means of diagonal braces, which made the assembly of additional shoring towers underneath the ceiling obsolete. When building the upper floor, load concentrations were absorbed by square shoring towers which the scaffolders had erected here and there in the intermediate bays. Around 100 tons of scaffolding material were used altogether – exclusively Allround standard parts with well-thought-out screw-less wedge lock connection.

To assemble the 600 square metre structure, this helped to speed up assembly to its experience. In view of the heavy loads, the scaffolding experts chose square shoring towers with a ground plan of 1.09 m x 1.09 m,
linked to Allround ledgers and diagonal braces by wedge head connectors and braced – meaning without additional connections using tubes and couplers. The combining of frames, in order to increase load-bearing capacity in the area of the almost seven metre high wall slabs too was achieved using Allround ledgers with short intermediate bays. During measuring of the shoring towers, the use of standard Allround Scaffolding components likewise permits a considerable time saving. After assembly of a single tower, the distance to the next tower results automatically with the system dimension from right-angled positioning of Allround ledgers on the ground.

Construction of Layher Allround TG 60

The scaffolding solution was also persuasive when it came to flexibility: the Allround Shoring TG 60 was able, thanks to its two shoring frames of differing height and by the spindle extension length, to compensate for height differences in the angled ceiling and in the slightly sloping ground. The width of the shoring was precisely adapted to the tapering form of the wall of the inlet and outlet structure by intermediate bays of variable width made from Allround equipment, or by extensions in the edge area using Allround standards. It was also possible using simple Allround brackets to build the working levels for the formwork on the wall slab and binding beam, or to construct the site accesses quickly using Allround stairway towers. 150 tons of scaffolding material were used in all, which Layher delivered to the site right on schedule and in a very short time when requested. The safe assembly sequence for Allround Shoring TG 60 automatically provides scaffolding erectors with all-round side protection, even without additional components, during upright assembly. 

This allows the valid safety regulations to be met in full for the first time. The use of the new Allround Shoring TG 60, thus ensured crucial advantages for Scaffolding Company: compliance with the tight schedules required by project planning, optimum working conditions for the formwork and a high degree of safety during assembly work.

For further information,
visit: www.layher.co.in 

Expanding Road Construction Equipment Business

by Sawon Banerjee | Oct 13, 2020 | Construction Equipments

Mr. Adarsh Gautam Head Sales & Product Support – Road Construction Equipment Division, Action Construction Equipment Ltd.

ACE – Action Construction Equipment Limited is India’s leading material handling and construction equipment manufacturing company with a majority market share in Mobile Cranes and Tower Cranes segment. ACE has a consolidated presence in all major infrastructure, construction, heavy engineering, and industrial projects across the country.

The company has been awarded the “Best Seller in Mobile Cranes Category” consecutively for the last three years and also the prestigious “Top Challenger Award” in construction equipment.

ACE equipment is used throughout the country and to cater to this wide spread and to provide effective pre-sales and after sales service, the company has developed a network of Dealers and Area Offices operating out of 100 Locations and supported by 15 Area/Regional Offices based at Delhi, Mumbai, Chennai, Kolkata, Ahmedabad, Pune, Jaipur, Raipur, Bhubaneswar, Lucknow, Indore, Hyderabad, Bangalore, Vizag and Cochin. These Area/Regional Offices are in turn supported by the Marketing HQ and a dedicated Product Support Division based at Faridabad. We also have an exclusive Toll-Free Service for our clients. They can give a call on 1800-1800-004 24×7 for any complaint and it will be attended within 24 hours.

ACE has always believed in innovation to achieve excellence. The group has introduced new technologies and new models across its product range at a phenomenal pace. The company also has a diverse portfolio consisting of wide range of products covering all segments of construction, earthmoving, material handling and agriculture sectors. 

ACE is building up its Road Construction Equipment business, with its 15 Ton class Motor Grader – AG 176. ACE Motor Grader offers higher productivity at a competitive cost. AG 176 has heavy duty AVTEC Transmission, Meritor axles and is powered by Cummins engine, which makes it comparable to the best in the world.

Also, the company has launched two models in Compactors category, viz 11 Ton Capacity Soil Compactor ACE ASD 115- and 12-ton capacity Soil Compactor ACE ASD 124. These models come in 3 variants viz. Standard Drive, Drum Drive and Pad Foot Drive. The major aggregates fitted in these compactors are Kirloskar Engine, DANA Axles, and Sauer-Danfoss Hydraulic Pumps and Motors.

In Tandem Roller category, we have 9-ton Capacity ACE ADD 95 Tandem Roller fitted with Kirloskar Engine, Sauer-Danfoss Hydraulic Pump and Motors.

Road Construction Equipment acts as a very important tool in the automation of Road construction business, and as per government’s vision of making 41 km roads per day and major boom in the infrastructure sector and road projects, we anticipate a huge demand for these machineries in the coming future.

Some of the key highlights of our Motor Grader are:

• 15-ton operating weight for higher load and traction.
• Powerful and fuel-efficient Cummins 6 BTA 5.9 Engine with 173 hp.
• Highest Drawbar Pull Force for faster and better productivity.
• High Blade Down Force for better cutting.
• Auto Lock and NO-SPIN Anti Slide Differential, Heavy Duty Axle from Meritor.
• Electro-Hydraulically Controlled Power Shift AVTEC/ZF Transmission.
• Fully Air-Conditioned Cabin for increased operator’s efficiency and comfort.
• Optional Ripper and Dozer attachments are also available.

Currently, we are operating from more than 100 locations at pan India level and are present at the most of the strategic locations with the dealers having spares stocked as per the population of machines, so as to cater the remotest site within 24 hours of complaint registration. We also have a facility of 24×7 helpline for our customers, to give them the best support at the earliest.

Most of the spares including the critical ones are stocked at our dealer points to ensure seamless support. We are conducting operator training on a regular basis at our dedicated training centre in Faridabad. Regular periodic training courses have been conducted to enhance operator and engineer skill levels. Also, we offer 15 days free training to every new customer. We cover all the aspects related to the operations and safety of the machine.

Also, the company provides option of Telematics which in turn digitises the equipment. It helps the owners of the machinery to remotely monitor and supervise the various functional parameters of the machine and remain updated of its health and maintaining the same to optimum level for better performance.

We have tie ups with almost all the financiers in the market. Our product is financed by all the finance companies at a very reasonable rate. Also, we have MOU’s with major players that help customers to get finance done at very lucrative rates.

A product with the key value proposition of “सही दाम ज्यादा काम” meets all the criteria a customer wants for a profitable investment.

For further information,
visit: www.ace-cranes.com

Wirtgen’s Cold Milling Machines Solve Big Challenges

by Sawon Banerjee | Aug 15, 2020 | Construction Equipments

North of Sacramento, a W 210i and W 2100 precisely milled the spillway chute of the Oroville Dam, the highest dam in the USA. In this process, the milling contractor also benefited from cold milling specialist Wirtgen’s application experience in steep gradient milling.

Temporary Solution Makes Milling In Two Passes Necessary

At an altitude of 235 m, the earth fill embankment dam on Lake Oroville dams the waters of the Feather River. After several weeks of rainfall, the dam reached its maximum water level of around 4.3 billion m³ in the winter after only 50 days. As a result, the owner, the California Department of Water Resources, had to initiate flood control measures at an early stage. The water was discharged in a controlled manner over the top of the dam structure at the level of the dam crown and the adjacent spillway. Due to the large quantities of water and the extremely high water-pressure, however, the 55 m wide, main concrete spillway eroded to such an extent that rehabilitation was unavoidable. The damage was initially minimized provisionally by filling the erosion in the surface with rolled concrete, “so that the owner could open the overflow system during the winter months, if necessary,” explains Chris Anderson, project manager at the subcontractor, milling service provider Anrak. This temporary material had to be removed prior to final concrete paving with Portland cement, however, to achieve the desired surface quality. To complete this task, the contractor decided to use two cold milling machines from Wirtgen.

Built-In Wirtgen Levelling System And Milling Drum Design Impress Contractor

Eight days had been scheduled for the removal of the first layer of rolled concrete.

Wirtgen Cold Milling Machines Prepared the Oroville Dam’s Spillway for the Repair Project.

Before the Cold Milling Machines could Begin
their Work, They were Lifted Onto the Surface
to be Milled by Lattice Boom Cranes.

The lower section of the spillway was about 300 m long. The milling depth required was approx. 5 cm. This job was performed by the W 2100 equipped with an ECO Cutter milling drum. This milling drum is fitted with up to 50% fewer picks at larger tool spacings (LA) than a standard milling drum. Fewer picks mean a lower cutting resistance, making it possible to mill hard surfaces such as concrete. This process was followed by the W 210i, with a standard LA15 milling drum to give the milled surface the finer texture required to pave the new concrete layer. During the job, both machines used the Level Pro levelling system developed by Wirtgen. According to Anrak’s CEO Tom Schmidt, this is a perfect symbiosis, “We have used almost every machine under the sun, but none can compete with the Wirtgen milling machine together with the Level Pro system. It is both reliable and extremely precise. The evenness of the surface is perfectly uniform, and the machine always has excellent traction. The latter is important when milling rolled or Portland cement concrete. And the vibrations that are unavoidable when milling such a hard surface don’t affect the Level Pro system one bit.”

Safety Played an Important Role During the Rehabilitation Project. To Protect the Workers and their Equipment, Cargo Containers Secured the Lower End of the Spillway.

Steel Cables Attached to a Wheel Loader Secured the Wirtgen Cold Milling Machines.

Logistical Challenges

After the flatbed trucks had transported the cold milling machines to the upper end of the spillway, the machines were lifted onto the structure with the aid of lattice boom cranes and driven onto the area in need of rehabilitation via specially constructed ramps. Here they faced the next challenge – milling on a 30° gradient. This challenge was solved by attaching steel cables with a total length of more than 450 m to the blades of a large wheel loader and to the rear of the large milling machines, thus securing the machines while work was being carried out. In the process, the heavy steel cables were attached to several hundred trolleys that are normally used for transporting heavy furniture to prevent them from rubbing against the ground. “We used the trolleys to prevent the texture of the freshly milled concrete surface from being damaged,” explains Tom Chastain, Applications Specialist at Wirtgen America.

At an Altitude of 235 m, the Embankment Dam on Lake Oroville Dams 
the Waters of the Feather River. This Makes it the Highest Dam in the United States.

Application Expertise And Safety Go Hand In Hand

The machines have a working width of 2.2 m, and it took an average of two hours to remove an entire length. “In order to achieve the desired surface quality, but also for safety reasons, the cold milling machines were operated at a low advance rate of approx. 3 m/min,” says Chastain. In the end, the W 2100, and the W 210i had each milled 28 full lengths. The cold milling machines loaded the milled material directly onto tracked vehicles with a capacity of 5 m³. These machines are mainly used in open-cast mining, but their excellent manoeuvrability also made them valuable for steep gradient milling at the Oroville Dam. As soon as the tracked vehicles were filled, they unloaded the milled material at the lower end of the spillway so that it could be transported to a nearby concrete plant. There, the concrete milled material was reprocessed into new concrete for the subsequent construction project.

After the “milling the spillway” subproject had been reliably completed within the scheduled time frame, the entire rehabilitation project costing
1.1 billion US dollars was completed on schedule after around two years.

For further information,
visit: www.wirtgen-group.com/india