New Screed Hopper

Last Friday I went to visit Total Concrete's new Stetter batching plant to get some shots of their new screed hopper. Rather than a long description of it, here's a short video showing what it does...

Training For Cats

Today was the second of two days of training in our offices conducted by a gentleman from Caterpillar engines. As readers may be aware, our static pumps all now come with Cat engines and so it is important for our engineers to fully understand the technical aspects of these.

This training was to bring us up to speed with the latest (full and final) specifications for diesel emissions using Diesel Emission Fluid (AdBlue being a popular example). This means our engineers are now qualified to maintain the latest generation of Caterpillar diesel engines.

As well as our own engineers, we invited engineers from a couple of our clients, Coinfords and Careys to come along to the training too - because the more our customers get out of their Schwing Stetter equipment, the better it is for everyone.

Swash No Buckle

A bit earlier I was asked to gather up some information about pump pressures with regard to the angle of the swash plate. Now not being an engineer, this term went straight over my head and so Hughie, the MD very kindly took some time to show me what this meant.

I had seen plenty of hydraulic system drives (the bit that that turns engine revs into hydraulic oil being pushed around the system) but had never known how one worked. I am pleased to say that now one more of the many wonders of hydraulic engineering has  been revealed to me, and very interesting it is too!

Basically a circle of cylinders and pistons connected to an angled plate spins. Both the cylinder block and the angled 'swash' plate spin at the same time so the swash plate pulls the pistons in and out as each cylinder/piston moves around the circle. The changeable angle of the plate determines how much the pistons actually move in and out for each revolution.

The pistons moving away from and out of the cylinder block are drawing hydraulic oil into those cylinder while the ones moving back into it are pushing the oil out, having brought it around to the other side, and so oil is forced to move continuously from one side to the other. Ingenious!

Seeing (and have a play with) the cut away working demonstration one above really helped me to understand what was going on. So now next time someone talks about the angle of the swash plate, I'll know what they mean.

Reptor Video

It seems, looking at the viewing statistic that you blog readers rather like the videos I put up from time to time and also stuff to do with the new S 38 SX 'Reptor' mobile pump.

Well then as a special Schwing Stetter May bonus - here for your viewing pleasure is a combination of both!


This short video showing the new mobile pump at work was sent to me this afternoon by our good colleagues in Germany and as soon as I saw it I thought I need this to be public so our customers and friends can see this amazing new machine at work.

Enjoy!

More Platforms

Such was the success of our new workshop mezzanine floor last year (and the new floor space over the new reception area) that we decided to add a double version at the other end of the workshop!

Once again the lads rose to the task and had the thing built and stocked in less than a month.

The view's not too bad from up there either!

A Great Reception

If there's one thing you can say about our engineers at Schwing Stetter, it's that they are versatile. We have recently been making some adjustments to the workshop area, extending the mezzanine floor and sprucing up the reception area. And it was none other than our own engineers who did the major work.

We now have quite bit more upstairs floor space to accommodate our expanding parts inventory, and a much nicer front reception area (as you can see above).

Here are a few photos from different stages of the work...

Staircase reversed

Our Engineers' steelwork taking shape

The floorboards down and the new reception desk

Extra space for more (genuine Schwing Stetter) parts storage

Our engineers even install signage (note the new ceiling is now in place too)!

New Platform

As we constantly strive for better ways to do things and increase our productivity, it was decided to make use of a whole lot of unused space a few metres above the floor in the back corner a create another mezzanine floor.

Robs design and workmanship once again came to the fore to build everything needed and over the last few weeks the whole thing was build and assembled from scratch. He was even able to tell me how weight each step was able to hold. Such a talented team we have...

The space to fill

Rob assembling the staircase

First part of steel structure in place

Structure taking shape

Flooring down

The view from the new platform

All finished

Animated Ability

The people at our Head Office in Germany have been busy of late. Alwyne, one of our very good sales chaps came back from Bauma with a memory stick for me with some really good animations which the Germans had put together. They show the new S 38 SX 'Reptor' boom opening and reaching into some really tight spots.

One of this blogs most popular posts has been the one showing the S 36 S reaching into the workshop space. These animations show how the new Reptor (as in Reptile - Snake like flexibility...) can reach into a difficult space in a similar manner, and also shows it opening up under a restricted height (7.4 metres since you ask).

I have put them both on a new web page on out website. You can also see them below...

Small Certification

Over a few months around the end of 2014 / start of 2015 we gained four National Small Series approval documents from the United Kingdom Vehicle Approval Authority, the VCA. This means that Schwing Stetter (UK) is:

"able to prepare for vehicles built in full conformity with this approval to be presented for registration."

The four certificates were for DAF, Mercedes, Scania and Volvo and mean we can mount mixer drums on these chassis and do all the bodywork with the national authority confident that the work will be carried out to the standard required for registration.

The actual certificates are three pages long and we decided it would be nice to display these, together with the vehicles they refer to. These four displays, shown above, now sit proudly in our board room.

Still Hold The Record

I was recently looking into records for concrete pumping and was pleasantly surprised to find that we still hold the word record for vertical distance pumping of 715m which was achieved using a Schwing SP4000S stationary concrete pump by the team working on the Parbati Hydroelectric Project in northern India back in 2009.

The project was to create two pressure shafts each 1550 m long x 3.5 m diameter inclined at 30° to create a vertical drop of 750 metres. The main contractors, Gammon India Limited, chose Schwing-Stetter to provide all the concreting equipment for the job including batching plants, transit mixers and concrete pumps.

The two tunnels had to first be excavated with a TBM from the bottom up and then a steel liner was installed by lowering each 6 meter section from the top and welding it in place as they went. The surrounding annulus then needed to be back-filling with concrete (around 7,000m³ for each shaft) and this was pumped from the foot of the shaft upwards over a total 1.5km length (and vertical rise of 750m) and into place. We are talking nearly ¾ of a kilometre upwards here!

A total distance pumped of 1½km in a single line push would be impressive in it's own right without even having any vertical component. Setting the vertical record at 715 metres at the same time is astonishing.

The concrete pressure reached was over 220 bar as they pumped to the top section and the concrete at the top continued to flow at 12m³/hr.

What is even more astonishing is that the SP4000 which did the work is a medium range pump and not even Schwing's most powerful model, which is the SP 8800. In addition to that, the only ware parts that needed changing  during the 7,000m³ concrete pour (plus around 2,000m³ of water) were two kidney seals.

To get some idea of the high specification of the machinery we are dealing with here, when cleaning out the pipe with water any gap between the main wearing parts in the pump would have made it impossible to generate the water pressure required. It would have come squirting out of the smallest of gaps. However even after setting such a record pumping concrete, the SP4000 was able to pump water at this pressure - proof of the self-sealing and low wear features of the Schwing ROCK valve.

The Schwing SP4000 not only set the world record for concrete pumping, it took the world record in its stride and kept going! What an amazing piece of engineering!

Innovation Award Shortlist

Back in February I mentioned that we had just solved a problem with a bit of innovative customisation regarding the opening of the drum flap on a mixer truck. Well it seems that the client wasn't the only one impressed by the work.

We have been shortlisted for the 'London Innovation of the Year' category of the London Construction Awards 2015.

Its nice to have our work recognised and it certainly shows what a great engineering team we have here. Here is a picture of the finished open drum flap on the truck having now been painted up.

If you want to see it actully working - there are a couple of short videos on our website customisation page here...

Crossrail Video

Back in October last year I was invited to go and visit one of the Crossrail sites where a Schwing pump was being used by Kelly Formwork to pour the concrete 'base' slab inside the rail tunnels. While there I took the opportunity to shoot some video of what was going on. I went back again last week to get some final shots and a couple of extra interviews. Here is the finished edited result...



On the day I was there Kelly Formwork used our SP3500 to pump concrete through over 1.3km of horizontal pipeline, finishing the pour in one of the tunnels and setting a new UK record for concrete distance pumping in the process.

Everyone involved was very pleased with the equipment and service Schwing Stetter had provided - and were happy to say so. It's always good to get positive feedback like this.

It was also really great to have a chance to experience the Crossrail project for myself, walk through some tunnels including under the Thames and see the tunnel development process.

Some Recognition

Having churned out numerous custom built truck mounted static concrete pumps and other bespoke work for customers, Rob our chief welder remarked that it was unfortunate that people who saw them out and about wouldn't realise we had done all the bodywork customisation as well. They'll just think we did the pump but they won't know we started with a truck chassis which needed to be cut down and added everything on there ourselves.

So we've had some plates and stickers made up to let people know. Here is Rob proudly mounting the first such plate onto a customised truck mixer. And here it is below...

Open To Ideas

A few mornings ago, Rob our chief welding engineer asked me to get some video of something he had just finished customising.

A client had asked if we could adjust a truck mixer so the drum flap could open all the way up so the mixture could be properly inspected. The answer was of course 'yes' - we are an engineering company after all. So here we have the hydraulic fully opening drum flap on a mixer truck, custom engineered by the Schwing Stetter (UK) team.

Apparently the client was so impressed they have ordered a whole lot more of them!

You can see how it works here below. The first video was taken before the safety guard was attached so you can see the workings. The second is after it was put on.






See more about our customisation on our website here: http://www.schwing-stetter.co.uk/Pages/Customisation.aspxhttp://www.schwing-stetter.co.uk/Pages/Customisation.aspx.

The Schwing Stetter Blog

Hi,

I'm Simon Densley and I'm the marketing manager here at Schwing Stetter (UK) Ltd in Perivale, London (or Middlesex if you want to be particular).

As well as upgrading the company website, organising ads to go in trade magazines and ordering branded clothing, there are many interesting things I find my self doing or finding out about in this role.

For a start, the products we sell are amazing. And I'm not just saying that 'cos I'm supposed to be marketing them. What I mean is the whole concept of pumping wet concrete through pipes and the pressures involved is mind blowing. As Hughie Byrne, one of the directors pointed out the other day, a hand grenade explodes at 40bar (which is around 40 times normal atmospheric pressure). Our pumps are pushing concrete through pipes typically at over 100 bar. Our most powerful machine (SP 8800) can push at 243bar. That's some serious engineering.

That means we can push concrete to the top of any skyscraper or the length of any tunnel. And every part of that system, including the steel pipes and the couplings that join them, have to withstand those pressures, not occasionally, but every day for years and years. And they do. Only working with jet engines I think would surpass concrete pumps.

Of course we sell other concrete related engineering products as well including truck mixers, batching plants and recycling plants and they are all astonishing examples of precision engineering in their own ways when you come to know about them.

The other really amazing this here is how good the engineers are at their job. They are so versatile and can seemingly not only fashion anything out of steel but can add some hydraulics to make it do stuff as well!

So seeing as there is so much interesting stuff going on here, it seems the time has come for a Schwing Stetter blog. Enjoy!