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Autocor® – Economical solutions forthe precast parts industry

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Process optimisation and increased efficiency with Autocor®

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✔Continuous pouring of concreteMore than 60 % higher productionParallel operations possibleBetter utilisation of plant equipment, floor space and crane

Conventional manufacture ofprecast parts: Overworked crane– crane is required for all stepsin the process

Interrupted pouring of concreteHigher personnel costs due towaiting timesNo parallel operations possibleCrane at full capacity: during concrete pouring, thecrane cannot perform other tasks

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✔Autocor® decouples crane operation from the concreting process

Schematic illu-stration of a con-creting processwith a mobileAutocor®

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Concrete pumps can deliver all pumpableconcrete recipes, whatever you manufac-ture - whether precast parts made of self-compacting or high-strength concretes,steel-fibre concretes or concretes withother special properties.

Placement of different mixes of concrete

Formworks can be quickly and continu-ously filled from above using rotary dis-tributors or MX stationary booms. Thisguarantees high-quality components.

Filling from above

Self-compacting concrete makes it pos-sible to manufacture exceptional struct-ural elements with excellent surfacefinish. In this process, the formwork isfilled from below via a connecting piece.

Filling from below

The pumpability depends on the compos-ition of the recipe. Account must be takenof a correct balance between aggregates,additives and admixtures as well as thewater/cement ratio (W/C). The formulat-ion alone cannot predict results, and sopumpability values have to be determinedby experiment.

To assess pumpability, Putzmeister hasdeveloped a new rheometer which allowsconclusions to be drawn for most types ofconcrete. Pump experiments then provideclearer evidence.

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The mobile Autocor® system

The mobile Autocor is a system consist-ing of proven Putzmeister componentsfor pumping and distributing concrete inprecast plants. A piston or rotor pump iscombined with a buffer storage and,where required, a flexible placing boomon a frame which runs along rails. Thewhole machine is controlled via radioremote control. The concrete pump oper-ator is located directly by the formworkand controls the whole system from thatposition.

The procedureThe control centre sends a signal to theconcrete batching plant to produce ameasured amount of concrete. This iscarried to the Autocor® by bucket con-veyor, placed into the buffer storage andpumped by the concrete pump into theformwork via the placing boom. Afterdelivery from the bucket conveyor, theconcrete is homogenised once again inthe buffer storage together with concretefrom previous batches. Because of thisthe fresh concrete is of such a continual-ly high standard. The pre-fab parts are inturn equally of a high standard whichmeans manual reworking such as smooth-ing and grinding are reduced to a min-imum. Almost all of the concrete in thepump and pipeline can be pumped intothe mould.

High level of efficiency – high qualityThanks to the almost continuous fillingof the formwork, an Autocor® increasesthe amount of production by up to 60 %while process costs are significantlyreduced.

Different pump systems for every power requirement

Mobile Autocor® with rotor pump and placing boom, with a maximum horizontal reach of 28 m

Mobile Autocor® with dual piston pump and placing boom, with a maximum horizontal reach of 28 m

The mobile Autocor® can be equipped with pla-cing booms from 16 to 28 m which are guidedby radio remote control

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Clean processThe concrete is delivered in a closedsystem (bucket conveyor – buffer storage– boom – formwork) and, as a result,remains very clean. Expenditure forcleaning the hall in terms of cost andeffort are significantly reduced.

No additional formwork liningrequiredBecause of its sensitive kinematics andcontrol system, the Autocor placingboom makes it possible to fill precastpart formworks of virtually any form ofcross-section. Formworks no longerhave to be additionally lined.The placing boom can be controlled withcomputer assistance (optional). The oper-ator is then free to concentrate fully onthe situation at hand and the filling of theformwork.

The batching plant, bucket conveyor and mobile Autocor® constitute a production line. The machine is cleaned at a designated area

The pneumatically operated end hose shut-offvalve at the end of the boom ensures that theformwork and manufacturing hall are kept clean

Laser scanners are fitted at the front and rear ofthe rail-guided frame, safeguarding the hazardareas. If there is an obstruction in front of the

machine, the Autocor® stops automatically.

The Autocor® control system can be integratedinto the control system of the entire manufactur-ing process

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The stationary Autocor® system

For the modernisation and optimisationof existing factory halls and processes,Putzmeister provide a wide range of sta-tionary concrete pumps and distribution.

Space-savingPumps and pipelines are ideal for deliver-ing concrete when there is very littlespace in manufacturing halls and hardlyany floor space available for transportingand distributing concrete.

Free crane capacityThe factory crane is no longer requiredfor carrying spreading buckets and canbe flexibly used for reinforcements,formworks and transporting precastparts.

High qualityPumping concrete directly into the form-work via a delivery line ensures that thematerial does not separate, The quality ofthe freshly mixed concrete and of course,as a result, also the quality of the finishedprecast parts always remains high.Formworks can be filled significantlyfaster.

Compact and powerful stationary pumps for precast part production

The hydraulic placing boom is extremely flexibleThe hydraulic rotary distributor with horizontal reach of up to 22 m is ideal for large-scale elementswhich are positioned on one level, such as sections of bridges

Whatever the delivery rate required, Putzmeister can provide the right concrete pump

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By using a diversion valve, various productionlines can be supplied with concrete and conveni-ently cleaned once concreting is complete.

Smaller sized formworks can be quickly and easily filled from a centrally positioned rotary distributor.

The illustration shows how Putzmeister machines deliver and distribute concrete efficiently in a precast plant: An electrically driven double piston pump is installed under the concrete mixer. An intermediate reservoir can also be provided as an option between mixerand pump (depending on the output of the concrete mixer). Various delivery lines laid above or below ground run from the concrete pump to the rotary dis-tributors and placing booms set up in the plant halls. Each of the placing booms which fill the formworks are supplied with concrete via transfer tubes. Theconcrete pump and placing booms are operated directly by the concreting teams at the formworks. The concrete which remains in the concrete pump and in the delivery lines can be pumped into the formwork so that cleaning is kept to a minimum after allformworks have been filled.

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We provide economical solutions for the manufacture of a wide variety of precast parts – worldwide

The MX 24-4 stationary boom travels along rails and assumes the task of placing the concrete in theformworks

Bridge sectionsTemporary factories are often built duringlarge-scale projects such as the con-struction of fast rail lines. Two BSA 1409D stationary concrete pumps are sup-plied with concrete directly from themixer. A travelling stationary boommounted on a lattice tower with a hori-zontal reach of 24 m assumes the task ofplacing the concrete in the formworks forthe bridge sections. The placing boom isconnected with the concrete pump via afixed pipeline and a flexible deliveryhose. Once all the elements required have beenproduced, the area will be used as a busstation.

Wind turbinesAutocor® has already been used tomanufacture the reinforced concretetowers of wind turbines for a number ofyears. Due to the size and number of the form-works which have to be filled every day,the Autocor® consists of the followingcomponents:■ Mobile travelling frame with laser

scanners at the front and rear andother safety equipment

■ Concrete pump with an effective output of 100 m3/h

■ Hydraulically operable placing boomwith 24 or 28 m horizontal reach

■ Buffer storage with a maximumreservoir capacity of 10 m3

The Autocor® is continuously suppliedwith concrete by a bucket conveyor.

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The BSA with extension hopper is located in thesame hall as the batching plant

The small containers are manufactured like on aproduction line. The diversion valve conducts theflow of concrete to the large or small forms.

Systematic illustration of the automated supply ofconcrete to two production lines. The mouldsslide onto transport rollers

Containers for waste water treatmentA BSA 1005 with extension hopper is feddirectly by the mixer, and pumps thesteel fibre concrete to a diversion valvewhere the moulds are filled as they passby on a production line onto transportrollers. Another hall in which special sizes aremanufactured is supplied with concretevia a hydraulic diversion valve. In thathall, a stationary rotary distributor with areach of 13 m has been set up to placethe concrete.

Wastewater shaftsAutocor® can be used to manufactureindividually shaped shaft tube sectionsquickly and easily. A double piston pumplocated underneath the mixer pumps theconcrete into the nearby production hallvia a pipeline. Manufacture pays for itselfeven when small quantities are involved.The system is ideal when used in combin-ation with a mechanical RV 10 concretedistributor and a P 715 concrete pump,which has been specially designed forrelatively low quantities per hour.

From its central position, the RV 10 rotary distributor can reach 30 moulds which are filled with self-compacting concrete in one work operation

Noise protection wallsAn Autocor® BQ 06 is used to producenoise protection walls for motorways.During this process, self-compactingconcrete is pumped into the formworkfrom below. The formworks have a max-imum length of up to 8 m.

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Sharp edges and a very good surface quality are the features of this technique

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Rotary distributorIf formworks of equal height need to befilled efficiently, rotary distributors arethe first choice. Their position can bemoved mechanically or electro-hydraul-ically and they have a reach of up to 22 m. The height of the rotary distributor can bedetermined individually. With the RS850tubular column system, the distributorrequires a floor area of only 1 m2.

Placing boomsPlacing booms with a horizontal reach ofup to 36 m (statically installed on a tubu-lar column in the hall) or 28 m (mobileon the Autocor®) make it possible to fillformworks without creating a formworkbed before. The optional EBC control system(Ergonic® Boom Control) makes operat-ing the boom even easier. The boom canbe moved with pinpoint accuracy simplyby using a joystick from the remote con-trol system. The control system also pre-vents the boom from being folded out toohigh and damaging the hall roof or otherelements in the hall such as hall cranes.

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Pouring systems adapted to the application

CDS 500The CDS 500 concrete distributionsystem is used in conjunction with amobile Autocor® when filling moulds“from below”.In the process, an arm which is movedhydraulically docks with the mouldswhich are standing in a line, fills themwith a specified quantity of concrete,undocks and cleans the connecting pieces. This can take place fully automat-ically or by manual operation.

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High-performance and low wear concrete pumps

Double piston pump,e.g. Autocor® 1005

■ Suitable for pumpable concreteswhich have to be pumped over longdistances in stationary systems

■ Steel fibre concrete and high-strength concrete

■ Due to the pump's design, more con-crete residue is left than with a rotorpump

■ Delivery rate up to 100 m3/h■ Delivery pressure up to 130 bar

Rotor pump, e.g Autocor® BQ 06

■ Suitable for pumpable standard con-crete and self-compacting concrete

■ Ideal for smaller factories using adaily quantity of concrete of up toapprox. 200 m3

■ Very little concrete residue■ Optionally available with active

cooling for use in hot climates■ Delivery rate up to 58 m3/h■ Delivery pressure up to 25 bar

An electric motor or diesel engine is used to drive a double piston concrete pumphydraulically by means of oil pumps. The delivery pistons are connected with eachother via drive cylinders and work in a push-pull arrangement.

With the rotor pump, a hose in the rotor housing is compressed by two revolving rol-lers and the concrete is thereby pumped forwards. As a result, the pump runs veryquietly in continuous operation and can be very accurately controlled.

Buffer storageBuffer reservoirs are used to homogenisethe different batches of concrete andkeep the concrete pump continuouslysupplied with concrete. Hopper exten-sions (for small mixers), jumbo troughsor mixer drums can be used as intermedi-ate reservoirs, and individually adaptedto manufacturing requirements.

Putzmeister recommends Liebherr truckmixer drums which have been so suc-cessful on so many occasions. They aredistinguished by the use of componentswhich are particularly maintenance-friendly and wear-free. The mixer drums are manufactured fromhigh-strength special steel 27MnB5 andprovided with end-to-end welded-onwear protection on the mixer coils. The drum geometry allows quick unload-ing with optimum mixing efficiency andmaximum loading capacity.

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Our aim is to reduce costs, whether for ascheduled service or during ongoingoperation of your machine.

Whenever you need help and advice, weare there for you in over 150 countriesworldwide, providing a professional andreliable service.

■ Putzmeister can deliver tested, guar-anteed original parts direct to yourdoor, 24 hours a day

■ Exactly the right parts for your require-ments: Delivery line systems andaccessories in the Eco, Key andProline quality categories. All partsrepresent value for money in terms ofservice life and purchase price

■ Using the appropriate Putzmeisteraccessories extends the servicespectrum of your machine

■ A selection of parts can also be or-dered online from our Internet shop

For information on spare parts, please contact: spareparts@pmw.de

For technical questions, please contact: services@pmw.de

■ 24-hour emergency service inGermany, which is soon to be extend-ed throughout Europe and beyond

■ Ergonic® Tele Service (ETS) enablesremote reading and transmission ofstatus and diagnostic data to our ownworkshop or a PM service partner viamobile data communication

■ Full service contracts, covering allmaintenance work and spare partscalculated per cubic metre pumped

■ Service packages made up of individ-ual maintenance and inspection tasks

■ Manufacturer’s inspection in accord-ance with the requirements of theVDMA (German Association ofMachine and Plant Engineering)

■ Expert, customised training coursesand seminars run by the PutzmeisterAcademy – in our own modern train-ing academy or at the customer site. (www.pm-akademie.de)

■ Expert consultation for large projects,e.g. in the areas of concreting logis-tics, concreting processes and con-crete technology.

Putzmeister Services Transparency of costs and high availability – worldwide

Putzmeister Concrete Pumps GmbHMax-Eyth-Str. 10 · 72631 Aichtal /GermanyP.O.Box 2152 · 72629 Aichtal /GermanyTel. +49 (7127) 599-0 · Fax +49 (7127) 599-520E-Mail: pmw@pmw.de · www.putzmeister.com

The Putzmeister Group Concrete Technology PCT · Mortar Technology PMTPipe Technology PPT · Water Technology PWTIndustrial Technology PIT · Belt Technology PBTUnderground Technology PUC

Right to make technical amendments reserved© by Putzmeister Concrete Pumps GmbH 2010All rights reserved · Printed in Germany(11002Sc)

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