Contractors World Vol 1 No 5 CONTENTS

Reports from around the world by industry specialists • construction • demolition • quarrying • mining

Volume 1 No 5

South Africa Construction of the stadiums for the FIFA 2010 World Cup

The second in-depth review of the latest innovations and news from Bauma - the world’s largest event for the construction industry.

South Africa - 12 page report on construction of the stadiums for the FIFA 2010 World Cup

Ecuador - New international airport for Quito

United Arab Emirates - Constructing new university complex.

UK - Update on London 2012 Olympic Games Page 2 Contractors World Vol 1 No 5 CONTENTS

SOUTH AFRICA - FIFA World Cup 2010 Stadiums 12 A general over view of the various stadiums and the construction works required for the various football games. 15 An in-depth article by the contractors on the City Stadium, Johannesburg 23 A review of how modern formwork systems have helped deliver the quality concrete finishes demanded

ECUADOR 6 A new international airport for the city of Quito is under construction. UNITED KINGDOM 9 Compact equipment helps increase safety during rehabilitation work on major motorway UNITED ARAB EMIRATES 10 Haulotte excels at University

25 Bauma 2010 - A display of optimism. Second review of some of the new products and innovations on display from companies large and small. 36 Hillhead 2010 - A preview of what will on show at this biannual quarry and aggregate business exhibition in the UK 37 London 2010 Olympic Games - a report on the current progress of some of the key structures.

EDITORIAL SYMBOLS Look for these symbols which indicate a link to a product brochure or link to a video.

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Contractors World Vol 1 No 5 Page 3 Published by VVV Limited Publisher: Roger Lindley Content compiled and edited by: Roger Lindley MCIM Editorial Comment Nick Johnson For those who enjoy football, the 4-yearly FIFA World Cup is with us again. For the first time, ©VVV Ltd. 2010 All Rights Reserved it is taking place on the African continent in South Africa - which will be remembered for CONTRACTORS WORLD the constant sound of tens of thousand of CML House vuvuzelas - 1 m long horns - droning in the 7 Bell Mead background. Love it or hate it, this is a sound Sawbridgeworth of South Africa and their way of expressing exuberance at sporting events. Herts CM21 9ES UK Within the construction industry, The World Cup 2010 will also be Tel: +44 1279 600598 remembered for delivering 10 stadiums, the majority of which are new, and Email: the many related infrastructures in time for the opening ceremonies. This is [email protected] despite the organizers and contractors being vilified for the lack of progress URL: in the construction stages and being in a position where the facilities would www.cwmags.com not be ready on time. As with the vuvuzelas, each country has its own traditions and way of Contractors World, CP&E - doing things - and this applies to the construction industry.. South African Contractors Plant & Equipment contractors are to be congratulated for delivering the stadiums to the high and other CW magazines and expectations of the FIFA Organizers and I am pleased to promote their supplements are independent publications. achievements in this issue, with extended reports on what was done as well as a detailed report from one of the main contractors. The mention of companies and/ In compiling these articles, it was also refreshing to talk to contractors or products within the editorial and Government departments that wanted to promote their achievements. pages or in advertisements does Here in London, there are many major projects in progress - the London not infer any endorsement by the publisher or editors. 2012 Olympic Games, the Cross London Rail Link (a railway tunnel running east to west underneath London), the Shard high-rise tower not to mention All editorial is freely given, the extensive, challenging road expansion on the London orbital road, the without conditions and at the M25. sole discretion of the editor. Reporting on these projects is made very difficult by clients not wanting publicity, contractors being under contractual restrictions not to talk to the Dimensions and specifications press, Government departments that have little interest in promoting British are given for guidance only and working practices illustrated are engineering capabilities and a general lethargy because of Health and not endorsed by the publishers Safety and other dubious litigious excuses. or necessarily meet specific And it is not only the UK that makes life difficult for contractors and local regulations. editors. It has become the norm rather than the exception; almost an enforced censorship on the freedom of the press to report positively on Copying, reproduction, decoding or disassembly of any content or activities. computer code by any means of By contrast, South African contractors and Cape Town Government have any part of the publication is gone out of their way to help promote their achievements. This is good for prohibited unless prior approval is provided by VVV Ltd. in the country and good for the contractors who may benefit from global writing and confirmation exposure to the work they can do. received of agreement with any I am also pleased to be writing more about Bauma 2010. With so much terms and conditions applicable. to write about, this will take a few months to give you all the important news from the various manufacturers. Some of the new products will take a while PDF version can be downloaded for personal use only. No part of to be available around the world, so there is no immediate rush. the publication can be used for promotional purposes without prior permission.

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Page 4 Contractors World Vol 1 No 5 Contractors World Vol 1 No 5 Page 5 CP&E Contractors Plant & Equipment Page 5 Quito, in Ecuador, is one of South America’s most dynamic cities. The population is growing continuously and scores of new developments are shooting up which means that the density of traffic is on the rise.

Quito Airport was no longer able to keep pace with these developments. Its location in the centre of the city and its sloping runway presented a substantial safety risk, as well as obstructing all plans for expansion.

The topology also presented problems, the airport is situated 2,800 m above sea level, making it one of the highest in the world. So the decision was made to build a new airport, “Nuevo Aeropuerto Internacional de Quito.” ECUADOR Paving the way on new international airport in Quito

Construction of the New Quito International Airport is currently the largest building project in Ecuador. The airport operator has invested US$600 million in the modern infrastructure, and the requirements on evenness of the runway and taxiways were every bit as high as the sum involved. The strict requirements were fulfilled with two SUPER 1800-2 pavers combined with AB 500-2 Extending Screeds, and the aid of the VÖGELE Laser Receivers used for grade and slope control. Construction of “Nuevo Aeropuerto Internacional de Quito” kicked off The site for the new airport is 25 km to the east of the capital at an altitude roughly 400 m below that of the old airport - still some 2,000 m above sea level. Construction commenced in 2006 after more than 30 years of planning. After completion, the airport will be able to handle 5,000,000 passengers a year. The runway will be longer than that of the existing airport, at 4,100 m, making it the longest in Ecuador. The cost-efficiency of aircraft also stands to benefit: the longer runway will reduce the consumption of aviation fuel at take-off, as less thrust will be required. What’s more, the efficiency of long-distance flights, in particular, will be increased as these have only been able to land at the old Quito airport with just 60% of their maximum take-off weight.

Page 6 Contractors World Vol 1 No 5 A rotary laser was in permanent contact with the VÖGELE Laser Receivers on the SUPER pavers to guarantee an even pavement, true to line and level.

Making the grade with grade and slope control All told, the airport operator has invested US$600 million in the project. Little wonder, therefore, that nothing was to be left to chance in the construction of the runway. The requirements on the paving were extremely high. One reason why the contractor opted for machines with grade and slope control technology. Two SUPER 1800-2 with AB 500-2 TV Extending Screeds were selected for the job. Both pavers were also equipped with two laser receivers and two Big MultiPlex Skis. All requirements fulfilled using advanced laser technology SUPER 1800-2: Facts and Figures The VÖGELE Laser Receivers installed on the pavers were used Maximum pave width 10 m to pick up an artificial reference. The reference was generated by a rotary laser that is in permanent contact with the receivers. They Laydown rate up to 700 tonnes/h detected every deviation of the machines from the specified grade Maximum layer thickness 30 cm and emitted signals for correction to NIVELTRONIC Plus. Transport width 2.55 m The non-contacting VÖGELE System for Automated Grade Pave speed up to 24 m/min. and Slope Control also stood out on the Quito job site because of Travel speed up to 4.5 km/h its ease of handling. When connected to NIVELTRONIC Plus, the PERKINS engine rated at 129.6 kW Laser Receiver is automatically recognized as a grade sensor and is immediately ready for operation. ErgoPlus® operating concept Because of the laser receiver’s large pick-up range, there is no Hardtop need to adjust the height of the mast to which it is attached while paving. This makes the system ideally suited for paving large areas. In fact, when constructing the runway, it was possible to achieve extremely accurate paving results as early as during the placing of water-bound base. The Big MultiPlex Skis were only needed for grade and slope control at a few points where the job site conditions precluded the use of a Laser Receiver. Two SUPER 1800-2 placed water-bound base The works on the Quito job site began with the placing of water- bound base, 250 mm thick. For this, the two SUPER 1800-2 pavers were combined with AB 500-2 Extending Screeds equipped with tamper and vibrators. They worked in 8.5 m width. A number of features proved that the machines were well up to the task despite the thin air at that altitude and the relatively rigid material. The most important

Non-stop operation without overload: one of the two SUPER 1800-2 placing water-bound base

Contractors World Vol 1 No 5 Page 7 PROJECT SPECIFICATIONS Caterpillar dozers and motor graders where used extensively in preparing the ground for the new airport. • 25 kilometres east of Quito among them was the well thought out machine concept of VÖGELE's • Length of section: 4,100 m “all-rounder.” This starts with the powerful PERKINS engine delivering • Width of section: 45 m 129.6 kW at just 2,000 rpm. The modern, quiet-running engine comes • Total area: 184,500 m² with an electronic management system for a constant operating • Pave width: 8.5 m speed. Furthermore, efficient cooling is also crucial to the success of • Layer Thickness: 25 cm major projects as the construction of the runway at Quito International • 38,000 m² terminal Airport. For efficient cooling, the SUPER 1800-2 comes with a large cooler assembly. Innovative air routing, in the system ensures optimal cooling of the engine coolant, hydraulic oil and charge air – even with the paver operating at full load and at high ambient temperatures up to 50 °C. The paving team was fully satisfied with the VÖGELE technology: “Despite the heavy workload, everything went smoothly. The SUPER pavers work like clockwork.” After this thoroughly positive experience, the asphalt surfacing will be paved with the same machines. Extensive ground preparation works The New Quito International Airport (NQIA), the most modern of its kind in South America, is being constructed with the support and guarantee of the Canadian Commercial Corporation (CCC), the Government of Canada’s international contracting agency. In 2005, CCC signed a $413 million contract to act as prime contractor for the construction of the New Quito International Airport in Ecuador. The main contractor is Aecon AG Constructores S.A and the clients are Quiport S.A. - a Concession owned by Aecon Group Inc., Andrade Gutierrez Consessoes S.A and Airport Development Corporation Quito City is construction appropriate infrastructures for the new airport with the construction of a new 4.2 km road and a water pipeline to the area where the new terminal building is located. The new airport will begin operating in 2011 and will have a capacity to receive more than four million passengers per year and a loading capacity of 270.000 tons. [CW] Videos courtesy of Aecon AG Constructores S.A. Ecuador 2009

Page 8 Contractors World Vol 1 No 5 K Rouse Civil Engineering is using a fleet of compact and reduced tail-swing excavators for added safety during life motorway reconstruction works in the UK.

England Challenge for Contractor on Motorway There is never anything easy for contractors having to work on busy highways, where it is essential to minimise disruption to traffic flow. Working with large plant and equipment, contractors are under pressure to keep lane closure as narrow as possible. In the past this had lead to some serious accidents as a result of excavators tail extending into the traffic lane during swinging. The availability of minimal tail-swing and zero-tail swing excavators means that contractors can now work safely in clearly defined zones without the risk of accident from protruding tail-swing. There will be much more of this work as regulations require all steel crash-barriers to be replaced with concrete barriers. This involves working on the central crash- barriers - the most dangerous working zone in any road working. This benefit is clearly illustrated by UK contractors, K Rouse Civil Engineering Ltd, who have had many years experience and many contracts on widening, replacing crash barriers and other maintenance/rehabilitation work on the extremely busy motorways in England. In the past few years, they have invested heavily in more compact, more manoeuvrable machines that have minimal tail overhang. Part of this fleet is now working on the trans- Penine motorway - the M62. Several kilometres of steel-fence crash-barriers need to be replaced with the now mandatory concrete barriers on one of the busiest sections of the M62 in Yorkshire. Prior to this, the contractors are also installing new drainage system. By using compact and zero tailswing excavators, the contractors have been able to keep the live traffic lanes as open as possible. The contractors are able to work with just one lane of each side of the motorway closed during the work. The contractor has deployed eight reduced tail-swing tracked excavators – four New Holland E235Bs and four new Holland E135Bs – and two compact radius new Holland MH City wheeled excavators. The E235B tracked machines are used in the central reservation as primary earthmovers to excavate the drainage channels, and their smaller E135B work predominantly on backfilling, the MH City machines are used to transport and install materials on site. As a result, they frequently work in the closed lane of the motorway. “Their great advantage in such a confined area is that they are virtually zero tailswing, which is obviously a very important safety feature in this line of work,” said Jim McGibbon, the company’s plant manager. It was this combination of safety and productivity that initially persuaded main contractor Balfour Beatty to employ K Rouse on the job. “They became aware of it through cross hire, and saw a distinct advantage of using the City machines along with other compact radius models,” he said. Now the company has been awarded the contract for similar work between junctions 29 and 30 of the M62 which is due to start shortly.

New Holland New Holland compact excavators with zero- or reduced tail swing are ideal for working in ‘live’ road projects where safety awareness has to be extremely high.

Contractors World Vol 1 No 5 Page 9 For both internal and external construction works on a new University complex in Dubai, the contractors use a fleet of Haulotte access platforms.

Work continues on major projects in Dubai, despite the economic recession facing all parts of the world. Roger Lindley reports on one such project.

UAE Haulotte excels at Duba University

Oger International has successfully completed the first phases in a Dh.1.5 billion construction package for building the new campus of UAE University in Al Ain. The construction project has been awarded by the Mubadala Development Company. Work on the new campus started in 2007 and all phases are due for completion by 2011. When completed the University complex will feature advanced teaching facilities as well as excellent recreational facilities and accommodation for students and staff. Structures include accommodation for 25,000 students, an Olympic size swimming pool, gymnasium, lecture halls, laboratories and a ‘Great Hall’ building including basement parking facilities and ground floor with a sloping roof structure auditorium. There is also a mosque. Being constructed in number of phases In the first phase, there are more than 116.000 m² slabs and walls requiring 25,823 m³ of concrete. Walls to be plastered exceeded 91,000 m². There was 84,790 m² of formwork, 150,000 m² of scaffolding, 18,100 m² of blockwork and almost 16,600 m² of tiling. Altogether it is estimated that over 500,000 m² of surface area had to be painted. To finish the project as quickly as possible, a work force of over 4,000 was employed enabling work to proceed, 6 days per week, simultaneously on many different parts of the project. With a total built up area of 53,000 m², the numerous structures are spread across a vast campus on the edge of the city of Dubai. With maximum building heights of 15 m (6 levels) and with work progressing on several buildings at the same time, the contractors deployed a large fleet of mobile access equipment for the vast amount of finishing work that had to be done. Because of their proven versatility, productivity and reliability, Haulotte equipment was used extensively. The large fleet of Haulotte machines was supplied and maintained by Dubai company, United Equipment Rentals, who had two service technicians permanently on site.

For reaching roof-lines contractors used Haulotte H15-18-SXL scissor- lift because of the large payload and working area it provided

Page 10 Contractors World Vol 1 No 5 A Haulotte H25TPX provided the reach, the stability, the payload and the manoeuvrability for various exterior wall finishing applications.

In constructing of the Olympic size swimming pool hall, Haulotte HA260PX articulated access platforms and H18SX scissor lifts were used for fixing roofing components as well as for installing the air-conditioning ducting. With a maximum working height of 18 m, and a 6 m x 1.89 m platform area, the H18SX makes it easy to handle and install large dimensioned products such as sections of ducting. It is easily repositioned for maximum convenience and provides a very stable working environment. Every structure had its own access requirement Similarly with the gymnasium where a spacious, stable access platform was required to install roofing elements. The perfect solution was the mid-range Haulotte H15SX scissor lift with the same platform dimensions and load capacity of 500 kg as the larger mode, but with a lower maximum working height of 15 m – more than sufficient for the structural height. The long reach of the Haulotte HA260PX access platforms, 16.2 m and maximum working height of 25.6 m were key considerations for installing electrical installations and in finishing the exterior surfaces. They were used extensively on the lecture and laboratory buildings. Maximum performance was required from the Haulotte H25TPX units used in fixing windows, installing seals and other finishing work on the highest building on the site – the accommodation units. The H25TPX has a maximum working height of 25.3 m, a maximum outreach of 17.4 m and payload capacity of 230 kg. Mr Giovanni Gulli, project director for Oger said “Access work platforms (AWPs) are critical to the works. They are used for all finishing works on the exterior walls. The reach they provide allows finishing work to be done while excavation works are still proceeding at ground level. Although we are using some scaffolding, AWPs are more flexible, provide better access, save time and are easy to move from one location to another. Safety is also important to us and we have a dedicated safety team. AWPs are proving to be extremely safe provided the operators are given the appropriate training.” Rental company provides service support United Equipment Rentals has successfully positioned Haulotte access work platforms on many projects throughout Dubai including the metro line, the new international airport and on many of the major structures in progress. Despite the difficult time facing the construction industry worldwide, United Equipment Rentals continues to build on its reputation with the support of the Haulotte Group and today has a fleet of over 400 units.

Haulotte

A Haulotte HA260PX access platforms - one a many working on a new University project in Dubai, UAE.

Contractors World Vol 1 No 5 Page 11 THE 10 FOOTBALL STADIUMS FOR THE FIFA WORLD CUP 2010 - SOUTH AFRICA- FACTS

Contractors World acknowledges the assistance provided by the MediaClubSouthAfrica.com and the photographs within this special feature. All images, unless otherwise indicated, are the copyright of Media Club South Africa and may not be copied or used without their permission.

It is not that long ago that the construction industry in South Africa was being heavily criticised because there was no way that the various stadiums could be completed in time for the numerous football games that are part of the 4-yearly World Cup organised by FIFA. All credit to South Africa for demonstrating that they are able to deliver projects built to very high standards. The following is a short summary of the ten stadiums used and the works done. Following are selected articles on some of the works associated with the construction phases.

only remaining section of the original stadium. For the © MediaClubSouthAfrica.com World Cup it will have a capacity of 94 500 seats, and 88 430 thereafter, making it the largest stadium on the African continent. Status: Major upgrade Cost: R3.3-billion (US$ 440-million) Architect: Boogertman Urban Edge Contractor: Grainaker-LTA / Interbeton joint venture Upgrade began: 1 February 2007

ELLIS PARK STADIUM Ellis Park, located in the city of Johannesburg and is normally the home to the Golden Lions rugby club and Orlando Pirates football club. It was used for South SOCCER CITY STADIUM Africa's win in the 1995 Rugby World Cup. An existing Soccer City, on the outskirts of Soweto, is the stadium built in 1982, it underwent minor upgrades for flagship stadium for the World Cup. It is a huge the World Cup. structure modelled on the shape of the calabash, Capacity: 61,639 seats an African cooking pot. Originally built in 1987, it Status: Minor upgrade has been enlarged and completely transformed in a Cost: R550 000 (US$7 200) massive reconstruction, with the west stand the Architect: DBM Architects

Page 12 Contractors World Vol 1 No 5 © MediaClubSouthAfrica.com It was the first concrete structure, which could accommodate only 2,000 spectators, built by the City Council of Pretoria in 1923. It has undergone minor improvements for the 2010 FIFA World Cup. Capacity: 49 365 seats Status: minor upgrade Architect: Ingplan Africa Contractor: No main contractor Construction began: September 2007

DURBAN STADIUM A brand new stadium built near the beachfront, Durban Stadium has transformed the city's skyline. Contractor: Rainbow Construction Upgrade began: July 2007

© MediaClubSouthAfrica.com It has been designed as a multipurpose venue, with attractions such as restaurants, shops, an art gallery and children's play areas. CAPE TOWN STADIUM There is also a cable car up its arch to a top A completely new-build, in the suburb of Green Point, platform providing panoramic views of the city and the Cape Town Stadium. ocean, and even bungee jumps from the top of the It has views of both Table Mountain and the ocean arch. and, in the distance, Robben Island. Built on Green Capacity: 69 957 seats (54 000 permanent) Point common and within walking distance of the Status: New construction popular V&A Waterfront, it has a capacity of 66 000 Cost: R3.4-billion ($450-million) seats. Architect: iBhola Lethu Status: New construction Contractor: Group 5 / WBHO / Pandev joint venture Cost: R4.4-billion ($600-million) Construction began: October 2008 Architect: GMP Architects Contractor: Murray & Roberts / WBHO joint venture Construction began: March 2007 NELSON MANDELA BAY STADIUM Nelson Mandela Bay Stadium in Port Elizabeth was the first of South Africa's new 2010 FIFA World Cup LOFTUS VERSFELD STADIUM stadiums to be completed. Loftus Versfeld Stadium, in Pretoria, is one of the Capacity: 46 082 seats (42 000 permanent) oldest stadiums in South Africa having been used for Status: New construction major sporting events since the early 1900. Cost: R2.05-billion (US$270-million)

Contractors World Vol 1 No 5 Page 13 Architect: Architectural Design Associates / Dominic MBOMBELA STADIUM Bonnesse Architects Contractor: Grinaker-LTA / Interbeton / Ibhayi joint Photo: Graeme Williams, venture © MediaClubSouthAfrica.com Construction began: March 2007

ROYAL BAFOKENG STADIUM

With host city Nelspruit's proximity to the Kruger National Park, Mbombela Stadium has a quirky wildlife theme, with large giraffe-shaped orange girders facing outwards on its exterior, and funky zebra stripes on the seats inside. A totally new construction, the stadium has a capacity of 43,589 seats. Status: New construction Cost: R1.05-billion (US$140-million) Architect: RL Architects Photo: Local Organising Committee Contractor: Basil Read / Bouygues joint venture © MediaClubSouthAfrica.com Construction began: February 2007 The Royal Bafokeng Stadium, in Rustenburg, was built by the Bafokeng Nation, which owns much of the platinum-mining rights in North West province. It PETER MOKABA STADIUM underwent minor renovations for the World Cup, Photo: Local Organising Committee increasing its capacity from 38,000 to 44,530 seats, © MediaClubSouthAfrica.com with the main west stand enlarged and given a new cantilever roof. Capacity: 44,530 seats Status: Upgrade Architect: BSP Architects Contractor: No main contractor Construction began: September 2007

FREE STATE STADIUM Home to the Cheetahs rugby team and Bloemfontein With a design inspired by the baobab tree, a Celtic football team, Free State Stadium in common sight in Limpopo province, the new Peter Bloemfonte. It was built in 1952 and upgraded in Mokaba Stadium in the city of Polokwane has a 2008 to increase its capacity to 45,058 seats, as well capacity of 45,264 seats. as improve security, lighting and turnstiles. Status: New construction Status: Upgrade Cost: R1.24-billion (US$150-million) Architect: ACG Architects Architect: Prism Architects Contractor: Ruwacon / Meyker Re Teng Construction Contractor: WBHO / Paul joint venture / Ikaneng Developments / Promania 128 joint venture Construction began: March 2007 Construction began: September 2007 Apart from the 10 stadiums, the South African Authorities also implemented many infrastructure related projects including upgrading airport facilities, road and rail systems. Common to all the works was to ensure a legacy for the future to ensure that the investments will benefit society in the future. [CW]

Photo: Local Organising Committee © MediaClubSouthAfrica.com

Page 14 Contractors World Vol 1 No 5 Engineering the Cape Town Stadium for World Cup 2010 A special report for Contractors World by Andrew Fanton, Cape Town Stadium (Green Point), Project Director, Murray & Roberts. Ten stadiums are being used for the competition, of which five are brand new constructions. The design and construction of one of these, Green Point, in Cape Town has offered South Africa’s mechanical engineers unique opportunities to innovate and deliver engineering solutions that will take environmentally sustainable technology in venues to a whole new level.

The lead mechanical engineering consultant for the Cape Town Stadium in Cape Town is WSP Consulting Engineers. Richard Goldschmidt, the project engineer, a member of the South African Institution of Mechanical Engineering, is a principal consultant for WSP and has been working on the stadium project for three years. Cape Town: an intelligent stadium The Cape Town Stadium has been purpose-designed to be the first of its kind in South Africa: the inaugural ‘intelligent’ environmentally sustainable sporting venue in the country. The final design for Green Point had to deliver certain key elements. These included water and energy efficiency, and a significant waste management system; off-setting; and operational guidelines on and targets for sustainability. To deliver this, the mechanical engineers had to think laterally, be very pragmatic and a little ingenious in delivering engineering solutions which would maximise efficiency and the use of resources and limit waste. They also had to be pioneering and ensure that the stadium could operate at a scalable optimum efficiency level both on a match day and a non-match day. The result is that they have been able to implement advanced solutions which embrace environmental considerations. A world-first in heating and cooling solutions The stadium’s heating and cooling structure is designed to deliver maximum energy efficiency. An engineering conundrum was how to design a stadium that, for the World Cup, will be used for matches taking place mainly on

Contractors World Vol 1 No 5 Page 15 winter evenings, and will be filled to pic: Bruce Sutherland, City of Cape Town capacity with spectators and support staff. After the tournament, however, the stadium invariably might only be used for capacity events every second or fourth week of the month; on all other days there might only be a minor staff complement working in the offices. The challenge was delivering a heating and air conditioning solution which would respond efficiently to either extreme. Traditionally, the standard heating ventilation and air conditioning (HVAC) solution for sporting stadiums around the world is a large air conditioning plant in the basement which gobbles up energy and is expensive to operate. Consultations with the Department of Environmental Affairs and Tourism (DEAT) indicated that energy efficiency had to be a high- ranking prerequisite for any HVAC solution; this led to a South African technological first. The stadium has a ‘first of its kind’ in terms of its size: a water-cooled variable refrigerant volume (VRV) cooling system. It is normal for these VRV systems to be air-cooled. The system has a number of benefits. Firstly, because of the centralised control system, it is possible to cool efficiently either small areas, like one office on non-match days, or the entire stadium on a match-day. Secondly, because the stadium was being designed from scratch, the engineers were uniquely placed to consider not just the best possible technological solution, but also the best possible aesthetic solution. Ordinarily, air conditioning units are add-ons: ugly boxes on the walls which spoil the clean lines of the interior space. The engineers worked very closely with the architects to ensure that all services, including the air conditioning, were hidden. Creating a brain for the building Perhaps the most revolutionary of these elements is an optimised central remote building management system (BMS) which links all the stadium’s electronic functions and so-called ‘third party’ services (such as plumbing, drainage, heating ventilation and air conditioning systems) to one single interface which is called a human machine interface or HMI. The decision to develop from scratch this fully integrated system – a ‘brain’ - for the pic: Bruce Sutherland, City of Cape Town building was a ground- breaking one: it is the first system in South Africa to link all stadium services to a single control point via a single cabled system. Environmental and economic benefits of the HMI The particular environmental and economic benefits of this particular engineering solution are that the venue can be programmed with adjustable systems for two

Page 16 Contractors World Vol 1 No 5 A fleet of Liebherr tower cranes provided coverage of the stadium and the surrounding precinct. distinct profiles: an event profile, and a non-event profile. With an event profile, systems can be activated prior to the event so that services function at precisely the time you want them. The services are entirely scalable – so if an event is located solely in one particular pic: Bruce Sutherland, City of Cape Town zone of the stadium, that is the only place that ventilation and air conditioning, lighting and other services will operate at that time. On days when there are no events in the stadium which, realistically could be the case for large parts of each week, it is possible just to use the minimum number of services that are required, thus significantly reducing running costs: principally electricity and water heating. Unprecedented levels of monitoring It is the monitoring of every aspect of the stadium which ultimately makes the economic and environmental savings possible. Ultimately, it is the exacting and all-encompassing level of monitoring that is the truly revolutionary feature of the stadium, and a real world-first. The HMI tells everything about the building: the security cameras, the temperature of the water, the ticketing system. The level of detail is unprecedented in a sporting venue. Naturally, this level of monitoring requires a lot of cabling. In a traditional venue, this much cabling would be extremely expensive as each system is normally stand-alone. What they have opted for instead is a structured 10 gig backbone of cabling around the venue. Effectively, this works like a network. Wherever you are in the stadium any piece of portable electrical equipment, whether that is a CCTV camera or a ticket gate can plug into the backbone and transmit information to the HMI. The cabling solution has delivered considerable savings from other key supply contracts associated with the project, as well as easing site maintenance: just one contractor was responsible for installation. Monitoring water consumption There is no doubting the strong environmental credentials of the project and the significant contribution of mechanical engineering solutions in delivering this. All showers and taps are low flow; and water meters are installed everywhere, meaning that in the future, any retail or leisure concession units will need to be fully aware of their water consumption. Even the roof is used for pic: Bruce Sutherland, City of Cape Town harvesting rainwater. The roof offered a particular mechanical engineering challenge. It is made from white, opaque glass. A computer fluid dynamic study was undertaken to ensure the temperature build up on a hot summer’s day would be acceptable to spectators on the top seating tiers, as well as to verify that the updraft of smoke exhausting from a possible fire below would be directed away from spectators. The roof has a unique geometry and is open over the field. Rainwater disposal was

Contractors World Vol 1 No 5 Page 17 Contractors used advanced solutions and equipment from around the world. Here Doka formwork is being used in construction of the high-rise columns.

possible only in two places on the roof, which meant a challenging design. Mechanical engineering achievements from the project The stadium has really put South Africa on the map as a world-leader in sustainable venue design and for truly ground-breaking innovation in mechanical engineering solutions. South African mechanical engineers have been able to establish new standards in this field and will now be regarded as the benchmark for integrated technological solutions and sustainability for the next generation of sporting venues. Cape Town Stadium, Cape Town The 68,000-seat Cape Town Stadium was handed over to the City Of Cape Town at the end of 2009. The new football stadium occupies 10.6 hectares and is ideally situated in the suburb of Green Point close to the city centre. It is a world-class venue, 100% FIFA-compliant and is now considered by many to be one of the best stadiums in the world. The R4.8 billion project commenced in 2007, nearly 85 years since the 130 ha piece of land on which the new FIFA Stadium is situated was granted to the Cape Town City Council in 1923 by the Union Government as an area for general public recreation and sports. The old stadium on the site, which was demolished on 2007, hosted many major athletic and other sporting events, while the golf course has occupied a portion of the Common for over a century. Construction joint venture The construction of the project was undertaken by a joint venture between Murray & Roberts and Wilson Bayley Holmes-Ovcon (WBHO). Earthworks were a challenge in that the existence of solid bedrock just below the surface meant that the stadium could not be sunk into the ground which created challenges with the superstructure and roof configuration due to height restrictions. The construction joint venture established several impressive initiatives including the Cape Town Stadium Training Centre and the Visitor Centre. The Cape Town Stadium Visitor Centre was closed at the end of September 2009 after nearly two years of service as a hub of information for locals and tourists interested in the progress of the stadium and re-opened in December 2009 as joint initiative by the City of Cape Town and the

Dynapac compactors, Komatsu excavators and Caterpillar motor graders at work on the stadium approach roads.

Page 18 Contractors World Vol 1 No 5 The architectural design of the roof structure called for high-level working in difficult situations. Safety was a high priority. The precision handling with the Liebherr tower cranes was essential in lifting personnel to position.

stadium contractor, Murray & Roberts/WBHO Joint Venture. The aim was to keep the public up to date with progress on the construction of the stadium and to build enthusiasm for the World Cup. The visitors’ centre also doubled up as the site where new workers were inducted and pic: Bruce Sutherland, City of Cape Town motivated. Utilising football analogies such as being a team player, the motivation and morale of workers was maintained and was an important factor in the construction of the stadium. A new Visitor Centre was opened by the stadium operators in January 2010. Architectural design - innovative, sustainable, functional The design for the Cape Town Stadium structure was created by GMP Architekten in cooperation with Louis Karol Architects, Point Architects and Urban Designers, Cape Town. GMP Architekten has designed some of the world’s most significant buildings and stadiums. The Stadium, at the foot of Signal Hill, is situated between Table Mountain and the Atlantic Ocean. This spectacular setting was the inspiration for the innovative stadium design. The stadium architecture focuses on the exterior appearance as well as the user experience inside the stadium. The interior is designed so that its entire focus is directed on to the playing field, creating an intense and exciting atmosphere. The exterior shell of the stadium was designed as an abstract, linearly arranged membrane. Its unique undulating silhouette, which is the result of the geometry of the stadium body, transforms the stadium into a sculptural object and intensifies its integration into the existing landscape. The glass fibre membrane consists of expansive concave elements that form a cohesive flowing facade that follows the stadium's undulating shape. The light coloured glass fibre emphasizes this effect with a visual sense of depth and animation. The surface is translucent and it absorbs and reflects blue skies, the red glow of sunset or the grey colour of stormy or overcast weather. The spectacular appearance of the stadium as it reflects the changing colours of the surrounding landscape is unique and almost ethereal. Respect for the environment and the context of the stadium The stadium has a double symmetrical design and its overall diameter is 264 metres with a height of 55 metres at its highest point. The design meets strict environmental constraints and has endeavoured to keep the stadium as low and compact as possible to blend into the urban and natural environments whilst retaining the functionality required of a world-class stadium. The roof and the stadium lighting are only visible from the upper areas of the mountain. Acoustic design features The design also minimizes noise in the surrounding areas. The exterior is covered with noise-reducing cladding in order to reduce external sound levels and the roof is designed to reflect noise back into the stadium. The double skin design of the roof makes it possible to accommodate unsightly cables and other service items and also serves to minimize noise. The roof structure is designed as an acoustic “body” with its own internal volume. The glass fibre membrane is partially permeable and this softer inner material disperses sound waves and absorbs sound into the body of the roof. The outer (top) surface is a fixed glass skin,

pic: Bruce Sutherland, City of Cape Town New Holland C175 skidsteer loads were used in preparing the pitch

Contractors World Vol 1 No 5 Page 19 During construction, it was not unusual for mist to spill over the top of Table Mountain and make for difficult working on the roof elements. which provides a hard resonant surface that also reflects sound waves back into the body of the roof. Through the sloping surface of the roof, sound waves are bounced back against the soft inner skin membrane, where they are further dispersed. The principle of utilising the air space inside the body of the roof as a noise buffer is one of the active design principles applied to the stadium. The key to this principle is the requirement that the “inner” (lower) and “outer” (upper) surface of the roof structure must have different densities and therefore display different acoustic performance characteristics. The suspend roof The 45,000 m² roof is designed as a suspended roof plane that focuses attention downwards onto the playing field. The roof is supported by an outer compression ring and an inner tension ring. Its pin joint truss design combined with tensioned cables allows greater flexibility in the overall design elements and is a more cost effective construction method. The roof was designed to have a minimal impact on the city's skyline whilst still being strong enough to withstand the frequent heavy winds that are experienced in the area. Heavy glass was used in conjunction with the truss system on top of a compression ring for the reduction of turbulence. The glass forms part of the roof structure, which was supplied by a joint venture between US and German companies, Birdair-Pfeifer. DSE, a subsidiary of the Aveng Group, fabricated the structural steel and platework components for the roof including the radial truss, cantilever truss and tangential beam system. Heavy rainfall was also taken into consideration and the roof was designed to ensure that water effectively drains to the two lowest points. This water will be used to fill ponds and water features on the common and to partially irrigate the area. The pitch grassed area measuring 290 m x 265 m x 48 m, was seeded in-situ utilizing 5 different types of winter rye. Surveying challenges at Cape Town Stadium The surveying teams at the Cape Town Stadium faced several challenges during construction. The complex design of this stadium includes a steel cable tensioned glazed roof which reaches 55 m at its highest point. John Trangos, Chief Surveyor for Murray and Roberts said that the team were faced with some unique survey challenges, particularly those relating to the correct positioning of the raking pylons. "The outside perimeter of the stadium was designed to accommodate 72 raking

Surveying was a challenge for the contractors because of the architectural design and high pylons. A wide range of cranes and access platforms also had to be deployed.

Page 20 Contractors World Vol 1 No 5 For lifting the roof elements, a large crawler crane (Manitowoc) was used . For lower levels, access platforms and scissor lifts were very much in demand

pylons of various heights from 34 to 54 metres high. The pylons support the roof and the overall effect is a wave-like configuration. A perimeter compression ring and an internal cable tension ring form the basis of the roof which rests on the raking pylons via the girder intersections on the underside of the compression ring." "The pylons each measure 3 m long x 800 mm wide and their upward and outward slant at 17.5 degrees was particularly challenging. The construction of the pylons was carried out in 3.8 metre lifts necessitating approximately 12 lifts per pylon. The survey team had to position the formwork for each lift. Due to the weight of the roof, the accuracy of these columns needed to be perfect with very small tolerances. Maintaining integrity of control was difficult because of the acute upward angles. This would have necessitated working from quite a few different stations around the stadium." "After discussions with GeoSystems Africa and Leica, we decided to erect a 16.5 m high x 2 m diameter reinforced steel and concrete beacon, right in the centre of the stadium and we then affixed a Leica 1200 robotic • Size of site - 18.5-hectares Total Station (TCRP to the top of the pillar." • Average number of workers on site Trangos says that they were fortunate in that the - 2,600 labourers, geometry of the stadium was such that it enabled a full - 450 supervisory staff view of the columns from the centre of the stadium. "This - 65 package subcontractors • Tension cabling - 7.4 kilometres of steel cabling in immediately gave us several advantages”. The fully the stadium roof automatic Leica Total Station was controlled from our • Roof glass - Covers 45,000 m² and there are about ground station via radio link so it could be left at the top of 9,000 pieces of glass the pylon for any period of time. This was ideal as we • Weight of roof - 4 500 t. could take all the necessary measurements of the raking • Highest point of stadium roof - 55 m • Materials pylons from one position. This also freed us up to do o 130 000 m³ of concrete other survey work inside the stadium. We were also able o 390 000 m² of formwork to utilise the Total Station from its position on top of the o 12 000 t. of reinforcing steel pillar when we positioned the steel segments on the roof." o Six million bricks

Videos © Produced by Communication Department, City of Cape Town, South Africa

Contractors World appreciates and acknowledges the assistance given by Murray & Roberts and the Cape Town Government Departments. All photographs in this article are the © copyright of Murray & Roberts and/or Cape Town Government and/or Bruce Sutherland and may not be copied or used for any purpose without express permission.

Contractors World Vol 1 No 5 Page 21 JCB fit for World Cup Duties in South Africa A fleet of nine JCB Teletruk forklifts were used during construction of the various major stadiums that are hosting games during the FIFA 2010 World Cup in South Africa. The JCB Teletruks have been used for a wide range of general material handling duties during the final construction and fit-out stages of hospitality suites and visitor facilities in and around six of the principal World Cup venues. The Teletruks were supplied by Clarklift South Africa (PTY) Ltd., the JCB Industrial dealer in South Africa. Two of the Teletruks were deployed at Soccer City, Johannesburg. There are also two machines working at the Durban Stadium and at Cape Town’s Green Point Stadium, while there is one machine on each site at the Royal Bafokeng Stadium in Rustenburg, Free State Stadium at Bloemfonte and Peter Mokaba Stadium at Polokwane. Mike Poxon, International Sales Manager - JCB Industrial, said: “The tasks at the World Cup stadiums required a forklift truck that was flexible and capable of working on rough ground - and the JCB Teletruk fitted the bill perfectly. ”The Teletruk provides a superior lift capacity and forward reach that extends over debris and stock piles of building materials, as well as a compact size and 4WD capability to handle rugged site conditions and limited working spaces.” Teletruks such as the 350 shown in the photograph has a maximum lift height of 4.4 m with loads of up to 3,500 kg. A Deutz diesel engine delivers 46 kW, sufficient for the heavy duty applications it is designed for. Maximum travel speed is 20 km/h and turning radius is 2550 mm for speed and manoeuvrability.

JCB

Power Supply to World Cup Stadiums The Turnkey & Rental Divisions of Barloworld Power, the Southern African Caterpillar dealer is providing standby power generators for the World Cup 2010 in South Africa “The regulating authority, FIFA, has laid down strict compliance standards that are non-negotiable and these aren’t restricted purely to the stadiums, but apply to the overall backup infrastructure which will support this game,” explains Kenny Gaynor, Barloworld Power’s chief executive. “More specifically this applies to installations such as medical care facilities, police stations and public transport networks that need to operate 24/7, keeping people safe and getting them home.” All ten official FIFA 2010 stadiums will run purely on generator sets, with Barloworld Power having secured contracts for fixed plant room installations at two of these venues, - Cape Town’s Green Point Stadium, and Peter Mokaba Stadium outside the city of Polokwane. For all the stadiums, the FIFA requirements are the same, explains Barloworld Power project manager, Jac Hough, who was responsible for the Green Point installation. “When switching to ‘island mode’, the generators power-up about an hour before the actual kick-off time, run continuously during the course of each game, and then for about one hour afterwards,” he explains. Two 2 000 kVA Cat 3516 generator units were specified for Green Point, one of which will run during the games with the other serving as a reserve unit. Barloworld Power’s contract for the Peter Mokaba stadium entailed the installation of a Cat 3412 (800 kVA) unit and a Cat 3512 (1 600 kVA).

Caterpillar

Page 22 Contractors World Vol 1 No 5 The Greenpoint Stadium in Cape Town has a Peri Scores In South Africa seating capacity of almost 70.000 and is the The German formwork manufacturer, Peri, has venue for eight matches during the World Cup. provided solutions to contractors working on four of (Photo: Wiehahn Ltd. / Terry February) the FIFA World Cup 2010 Stadium projects in South Africa. The logistics for each site was coordinated by Wiehahn, authorized PERI dealer in South Africa

The Greenpoint Stadium in Cape Town and the Moses Mabhida Stadium in Durban will be the venues for the two semifinal games, which take place in front of almost 70,000 spectators in each case. The 34 cm thick reinforced concrete slab of the seven-storey high grandstand in the Greenpoint Stadium was formed using Peri panel slab formwork Skydeck with Multiprop slab props. Because of the low weight of the individual aluminium components and the simple assembly sequence, work could be carried out both quickly and fatigue-free. A benefit to the speed was the Skydeck drophead system which enabled short striking PERI Skydeck and the Multiprop load-bearing system accelerated times on both panels and main beams, thereby the construction progress for the realisation of the storey slabs of the Greenpoint Stadium. making the formwork available for the next cycle

At the Moses Mabhida Stadium in Durban, Peri Vario GT 24 wall formwork elements were completely pre- assembled and delivered ready-to-use. (Photo: Wiehahn Ltd.) Contractors: • Murray, Roberts, WBHO Joint Venture • (Greenpoint Stadium, Cape Town) • WBHO, Group Five, Pandev Joint Venture • (Moses Mabhida Stadium, Durban) • Basil Read, Bouygues Joint Venture • (Mbombela Stadium, Nelspruit) • Ruwacon, Sanyati, Ikaheng, Promania Joint Venture (Vodacom Park Stadium, Bloemfontein) • Field Service: • Wiehahn Formwork and Scaffolding (Pty) Ltd., Stellenbosch, South Africa

Contractors World Vol 1 No 5 Page 23 in a very short space of time. The slab heights varied throughout the project, but the large extension length and high load-bearing capacity of the Multiprop proved more than suitable. Used with the Multiprop frames, the slab props were also used as shoring towers. This meant that the cantilevered formwork for the slab edges could be supported for the height of several floors with the loads being safely transferred to the ground. Supplementing this were the Trio and Vario GT 24 wall formwork systems for the stairwells and lift shafts. Different Stadium - Same Systems At the Moses Mabhida Stadium, the contractors used Trio panel formwork The Mbombela Stadium in Nelspruit is situated close to the Kruger and the VARIO GT 24 girder wall formwork National Park and can hold up to 45,000 spectators. (Photo: Wiehahn for the construction. Ltd.) The Trio system offered sufficient versatility to meet the concrete forming requirements for the ballast tanks underneath the stadium structure together with the architectural fair-faced concrete walls of the five access tunnels to the pitch. The system was also used in forming the three enormous abutments for the arch support structure of the stadium roof. The Vario GT 24 wall and column formwork system was used for the construction of numerous reinforced concrete columns and elevator shafts as well as the inclined grandstand support beams, which had to formed to a very demanding specification and accuracy, with a high concrete quality cast in-situ. For the construction of the Mbombela Stadium in Nelspruit and the Vodacom Park Stadium in Bloemfontein, the Peri Multiprop system was again used to provide high load-bearing capacities and a high degree of flexibility as individual slab props and frame-connected shoring towers. Multiflex girder slab formwork combined with UZR beam walers were used to build both slabs and beams. Using GT 24 formwork girders allowed large spans which meant intermediate supports could be avoided as far as possible. For these two stadiums – each holding 45,000 spectators – the formwork and scaffolding concept was supplemented by Trio and Domino wall formwork systems as well as Vario GT 24 girder wall formwork.

PERI

As a load-carrying system for the Vodacom Park Stadium in Bloemfontein, PERI MULTIPROP aluminium slab props were connected with MRK frames to form load-bearing shoring towers. (Photo: Wiehahn Ltd.)

Page 24 Contractors World Vol 1 No 5 a show of optimism

Contractors World Bauma Review - A Show of Optimism - Part II

Manufacturers and visitors continue to comment on the success of Bauma 2010 - not withstanding the many difficulties faced. The general optimism felt at the exhibition would appear to be spreading throughout the construction industry. Although it is too early to give definitive indicators, there are signs of a possible recovery in parts of Europe, North America and Asia, particularly India. There are also some positive indicators from the Arab countries but they still have serious economic difficulties to overcome. Here is a second look at some of the new products and innovations that were on show at Bauma - new solutions that will, over the next few months be available in markets around the world.

Doing it in style - the Wirtgen Group shows its strength and leadership Under the guidance of Jürgen Wirtgen and Stefan Wirtgen, the family-owned business Wirtgen Group has grown significantly over the past two decades to become a global leader in the construction industry, the quarry and aggregate business and surface mining. Through their management policies, the four companies in the group - Wirtgen, Vögele, Hamm and Kleemann - have retained their individual identities whilst benefiting from the shared research and development synergies that being part of a group can bring. The Wirtgen Group continues to utilize all strategic options enabling it to emerge from the present economic crisis stronger and to increase the efficiency of both the main plants and the entire sales organisation. In 2009, the Wirtgen Group generated a consolidated total turnover of €1.18 billion Euros. This optimism and direction was evident in the Wirtgen Group stand at Bauma 2010, which covered a total areas of over 9,000 m². Although each group company had its own dedicated zone, there was no doubting that it was one big stand and the four companies shared a common hospitality and visitor information centre. Some 75 machines were on display which included the new generation of cold milling machines from Wirtgen, the largest road paver from Vögele, new pneumatic-tyred rollers from Hamm and innovative impact crushers from Kleemann. Not only has investment been maintained in R&D but signficant investments also in new facilities. Earlier this year, Kleemann GmbH moved into a new production plant at the Göppingen location -a facility with a total production space of over 35,000 m². Building operations at the new main plant of Joseph Vögele AG in Ludwigshafen are in full swing. When completed this will be the world’s most modern plant for the production of road pavers covering a floor space of 37 hectares. It will be fully operational by the fourth quarter of 2010. The Hamm and Wirtgen facilities also continue to be upgraded and given the necessary investment to delivery the technological advanced machines that the group is developing.

The Wirtgen Group

The Wirtgen Group is the market leader in mobile machines for road construction and road rehabilitation. The family business is managed by Jürgen Wirtgen and Stefan Wirtgen.

Contractors World Vol 1 No 5 Page 25 a show of optimism

Contractors World Bauma Review - A Show of Optimism - Part II

Sometimes two are better than one, but not always - new dual engine W 120 milling machine Wirtgen has taken a radical look at the way in which its large milling machines are powered. In many milling applications, some tasks require a large amount of power, while at other times, the power requirement is significantly less. A simple solution would have been to have a high capacity engine but, even when idling, such engines can be very thirsty. The solution, which, the company claims, can save up to 25% in fuel consumption, devised by Wirtgen R&D was to put two engines in parallel in to the new W210 milling machine - a compact large milling machine that can be equipped with milling drum assemblies of 1.50 m, 2.0 m or 2.20 m working width. Equiping the W 120 with two 6-cylinder Cummins diesel engines efficiently splits the machine’s drive power: the first engine has an output of 276 kW, and the second engine has an output of 224 kW. This enables one engine only to run in case of lower requirements, such as transport mode or idling times. The machine operator not only independently controls and Intelligent solution resulting in significant operates all major functions of the cold milling machine, such as savings: the total drive power of the W 210 of selecting the milling gear, but is also the one who decides when to 500 kW / 671 HP is divided into 276 kW / 370 HP for the first and 224 kW / 300 HP for the use the second engine during the milling process. Engine selection second engine. is via a simple key switch position change. When switched off, the second engine does not immediately close down, but enters a cooling mode before closing down automatically. Controls have been minimized for operator convenience and are duplicated either side of the operator’s platform. Using an external attachment, the machine can even be operated by the roadside team. No fewer than 6 video cameras give the operator a clear view of all sides of the machine. All major functions are linked through the management system for operating efficiency. The W 120 benefits from Wirtgen’s PTS system - parallel to surface which automatically aligns the machine parallel to the surface in

[Left] Dual controls allow the operator to work from the most convenient position. Many modes of operation of the new W 210 large milling machine can be performed using one engine only. These include transport travel, repositioning the milling machine on the construction site, or standby operation of the milling

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both longitudinally and transverse directions. The track mounted, 28,186 kg, W 120 has a maximum milling width of 2,000 mm, to depths of 330 mm. It has a mechanical drum drive with three selectable milling drum speeds for large-scale surface course rehabilitation; complete pavement removal at full depth; fine milling, or as required. For optimum material management, the discharge conveyor can be angled up to 60º either side. Width, depending on configuration is a maximum of 2.7 m.

World Exclusive - Vacuum Cutting System Particulate filters for engine emissions are specified in some areas, however, some people point out that the harmful particles they collect from engine emissions are just as common in the dust on construction sites - particularly in road milling applications. The Vacuum Cutting system (VCS) launched at Bauma by Wirtgen reduces the amount of airborne material particles which are produced by the milling process. Wirtgen GmbH is the only manufacturer worldwide to offer such a system for cold milling machines. The system works by mixing the material particles with water vapour inside the milling drum. The material is then collected and ultimately fed into the stream of material travelling up the discharge conveyor. Apart from minimising harmful dust particles, the system also significantly improves operator visibility and contamination of the engine filters. The system can be fitted to most of the Wirtgen cold milling machines from the W 100 up to the W 2200. Independent laboratory tests have shown the effectiveness of the VCS system and, on the basis of these tests, is recommended by the Employer’s Liability Insurance Associations.

Strip and rehabilitate a full-width highway lane in one pass Already well established and proven, the Wirtgen 2200 CR is a four-tracked cold recycler typically has with a working width of 2.20 m. This model is now available with a milling and mixing drum unit featuring a working width of 3.80 m - typical highway width - and a milling drum capable of working in the direction of travel, that is, in the so- called down-cutting mode. The new drum assembly offers a maximum working depth of 150 mm for the recycling of damaged asphalt layers. Equipped with a spreading auger and Vögele paving screed type AB 375 T, the 2200 CR now makes it possible to place and pre-compact the recycled mix immediately in an in-situ process. This option offers higher productivity, more efficient use of the machine and reduces time and inconvenience. Typically, the 2200 CR uses the down-cutting process, in which the drum rotates in the machine’s direction of travel, permitting better control of the size of the milled asphalt material. On some contracts, this requirement can be part of the contract. However, by simply exchanging the drum gearbox, it can be converted to work in up-cutting mode whenever required. The model has already been successfully deployed on several in-situ cold recycling projects in the North American market. Wirtgen is now rolling out the option to Europe and other parts of the world.

All-in-one full-lane rehabilitation with new option for 2200 CR from Wirtgen proven in the USA

Contractors World Vol 1 No 5 Page 27 a show of optimism

Contractors World Bauma Review - A Show of Optimism - Part II

New easier and faster extraction tool for milling machines Alongside a virtually self-explanatory display of damaged, broken, worn and abused surface milling cutting tips, Wirtgen allowed visitors to try for themselves a new tool that makes it very simple to change tools on milling machines from the smallest through to the largest models. The tool is designed to encourage contractors to replace bits as necessary. There are different variations. Contractors can choose between a hydraulically assisted tool extractor with integrated drum turning device control or a battery-operated hydraulic tool extractor. How easy? An average extraction time per cutting tool of between 2 and 5 seconds. It cannot be much faster.

Further enhancements on the way. Standing alongside the world’s largest surface miner - the 4200 SM, which was being shipped to Australia immediately after Bauma, Contractors World was told that there are other developments impending. The company showed how it was not only focused on new innovations but on enhancing existing models, for instance an improved dowel bar inserter for slipform pavers - and delivering more customer services. Technology will also become a more important part of surface milling technology.

Wirtgen GmbH

High-performance feeder empties mix lorry in 60 seconds. On entering the Vögele section of the Wirtgen Group stand, one could not help noticing the impressive length of the Super 3000-2 tracked paver, which sets a world record with a laydown rate of 1,500 tonnes per hour and paving widths up to 16 m (pictured left) This model was released pre-Bauma and featured in the February issue of Contractors World. However, there were two new MT 3000-2 feeders which, the company claims, can empty a mix lorry in just 60 seconds. The MT 3000-2 Offset is more versatile, with far greater performance than its predecessors because its belt conveyor can be pivoted to the left or right by 55° and vertically inclined by 23°. With this flexibility, the feeder can be used for feeding pavers from the side, backfilling trenches or filling the cavities in safety barriers during motorway construction, as well as reconstruction work on hard shoulders. The PowerFeeder MT 3000-2 Offset was designed primarily as the ideal machine for Vögele’s "hot on hot" paving process. This is because a number of criteria must be adhered to when feeding the pavers for binder

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course and wearing course in an in-line paving train: a large range and adequate conveyor height and a receiving hopper that can be completely emptied. Using advanced laser The MT 3000-2 feeder with or systems, the feeder is always without offset feeder, from Vögele, can empty a 25 t truck correctly positioned relative to load in less than 60 seconds. the paver. In large scale road projects, the daily lay-down rate can be as much as 4,000 t. The MT 3000-2 Offset has a receiving hopper capacity of 8 t proportionally control work conveyors with hydrostatic drive and 400 mm worm blades and the 1.1 m wide trough-shaped conveyor can carry up to 1,200 t per hour. With this configuration, it can empty 25 t of mix from a highway truck is less than one minute. The feeder is powered by a fuel-efficient DEUTZ diesel engine with an output of 160 kW at 2,000 rpm The drive system is compliant with exhaust gas emissions standards COM 3b and US-Tier 4i. A 380 litre fuel tank is sufficient to complete a full shift without refuelling. Operating speed is 24 m/min maximum and travel speed 4.5 km/h. Maximum width is 3,680 mm. From the platform, the operator can swivel in his seat through 30º and be swung out to the side. It can turn a full 180º when swung inside the platform For optimum material management, Vögele has opted for a newly developed diesel heating system, in place of gas cylinders, to maintain the conveyor belt at the correct temperature. The convenience of having only one fuel helps lower costs and saves time. Not every customer requires an offset feeder system, so the company offers the basic PowerFeeder MT 3000-2 without the offset option. Otherwise the machines are identical.

Joseph Vögele AG

New generation of rubber-wheeled rollers. The Wirtgen Group company, Hamm, unveiled the HD+ 90 and HD+ 110 mid-range rollers and the new generation of CompactLine rollers earlier in the year (See CP&E Contractros Plant & Equipment Vol 1 No 2) but did not pre- announce everything - in common with most manufacturers. It was only during Bauma 2010 that the company announced the GRW 280 - the first in a new generation of rubber-wheeled rollers. It is 40 years since the company created a milestone with the first all-wheel drive, all-wheel steer, rubber wheeled roller. They say that the newest introduction establishes another milestone because of its revolutionary and future-orientated concept. The GRW 280 roller features a completely new cab designed positioned for better operation. The cab is mounted on a newly designed asymmetrical frame and positioned well to the front of the machine for optimum operator visibility. The cab benefits from just a single seat, steering wheel and control panel instead of the former double system. This provides more space, and optionally, the seat, and console, can be moved and pivoted at the side, towards the machines outer edges. Speed is no longer controlled by foot pedal. The direction and speed are controlled

The large, forward positioned, cab on the new Hamm GRW 280 roller gives the new range a distinctive appearance.

Contractors World Vol 1 No 5 Page 29 A show of optimism

Contractors World Bauma Review - A Show of Optimism - Part II

The cab on the new Hamm roller is spacious and features only one seat, steering wheel and console which the operator can position form side to side as required.

by joystick for operator comfort and convenience. The tyres are positioned to overlap for full width compaction in a single pass. The new GRW 280 rubber wheeled roller is available in various basic weight ratings (10 t, 12 t, 16 t, 20 t, 24 t, 28 t). The machines can accommodate different amounts of ballast depending on the basic weight. The outer dimensions are identical for all Service points are grouped variants. under the engine canopy which is illuminated by the cab Power is supplied by a Deutz 4-cylinder diesel engine with rated output of mounted light for service checks 100 kw/2,300 rpm. The hydrostatic drive has a infinitely variable working in poor light conditions. speed up to 9.5 km/h and a transport/travel maximum speed of 19 km/h. For easier transport, height is under 3 m. This not only simplifies transport on a low-bed trailers, but also working under bridges, protrusions or other overhangs. The design considerations of the new roller are well conceived. By positioning all maintenance points on the engine's right-hand side, this area is illuminated by the cab lighting and so the drive unit can be inspected even in darkness. Another example is the ballasting system. In the middle of the machine are the large ballast spaces located between the wheel sets and the open compartment frame below. Loading and unloading can be carried out with minimal effort. The concrete or steel ballast bodies are conveniently inserted or taken out using a hand-lift or forklift truck.

Hamm AG

New “EVO” generation of mobile impact crushers Bauma saw the introduction of two newly developed mobile crushers from Kleemann - MR 110 and MR 130. The smaller model, depending on configuration has an operating weight of 43,000 kg has a feed capacity of up to 300 t/h, a crusher feed opening of 1,020 mm x 800 mm and a rated engine power of 291 kW. The larger MR 130 model has a maximum feed capacity of 400 t/h via a crusher feed opening of 1,300 mm x 900 mm. This model has an operating weight of 53,500 kg and a rated engine output of 337 kW.

Kleemann EVO technology displays plenty of innovation when used in new crushers.

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To cope with the greater overall performance, the surface of the screening units has been significantly enlarged, for example by over 44 % for the MR 110 EVO.

Designed for a wide range of applications such as processing limestone, reinforced concrete, bricks and asphalt to high-quality final aggregate fractions. For efficient discharge of processed material the flow concept ensures that there is no restriction to the material throughout the entire plant. The discharge chute under the crusher is 100 mm wider than the inner width of the crusher and the discharge belt which comes after this is a further 100 mm wider than the discharge chute. The independently vibrating double-decker grizzly, a key feature of Kleemann’s for some time, improves cost efficiency of the machinery. In the new EVO plants, the vibration behavior of the screen and vibrating chute has been improved for even better performance. Within the impact crusher, the rotor ledges are locked in position by a new and user-friendly clamping system. This reduces service times and increase machines availability. The hydraulically operated crushing gap can be adjusted via the electronic control unit and the calculation of the zero-point is possible while the rotor is running. Design for economical operations, efficiencies come from an direct drive and a latest-generation diesel engine which transmits its power almost loss-free via a robust fluid coupling the V-belts directly to the flywheel of the crusher. This drive concept enables enormous versatility, as the rotor speed can be adjusted in four stages. For example, the machines are equally well suited to use in quarries and in recycling, where the input material is often highly inhomogeneous, particularly for difficult processing of construction waste. Another extremely important feature for capacity and quality is the new classifying screening unit, which has been enlarged by 45% and which enables a closed circuit and thus the production of a defined final grain. Even for sieving grains up to 35 mm, the machine can make use of its full capacity without reducing the input volume. A swivelling return conveyor enables optional discharge of oversized particles to the waste rock pile. Brand new purpose built facility This new generation in mobile crushing technology is made possible by the investment in the R&D and manufacturing facility by the Wirtgen Group at the Kleemann plant in Germany. The new production facility, which was inaugurated at the beginning of this year, has over 35,000 m² of under-roof production space and will accommodate the enormous dimensions of its crushers and screens. “The new plant now gives us the production capacities we need to fill the additional demand from the new markets we are entering,” explains Markus Wörner, General Sales Manager of Kleemann GmbH.

Kleemann GmbH The Wirtgen Group is showing confidence in the markets and their commitment to customers worldwide by maintaining investment in plants - this the newly built Kleemann facility - as well as research and development.

Contractors World Vol 1 No 5 Page 31 a show of optimism

Intriguing concept in tower cranes but . . . ? Visitors to the outdoor area at Bauma 2010 could not have failed to see the most unusual tower crane configuration of the Double Jib GG 42085 e-Tronic crane. The concept was patented in 1968 and consists of a central towered base with two symmetrical jibs on each side. The company claims that it increases work efficiency by 50% compared to a traditional tower crane and increases lifting capacities with the rotation technique using electro- motor driven propellers. Jib length is up to 150 m. The operator swivels to manage each trolley, hook and load - controlling only one at a time. The success of the concept is dependent upon pick up and points of delivery being diametrically opposed. Although it has been proven on some building sites and does have some potential productivity enhancements, Contractors World believes that the opportunities are limited to some very specific applications. There may be potential in ship to shore loading applications. Many people Contractors World spoke to found the noise of the propellers an irritant although the crane was being demonstrated in continuous rotation so was not typical of the sound levels in normal operation. With many sites requiring more than one tower crane and more and more restrictions on over-flying or ‘collision risks’, the cranes rotation capacity would be severely restricted and contractors will have to evaluate to potential benefits against the higher cost. Many will consider that two independent tower cranes to be a preferable solution as each hook can be work simultaneously and, if zoning permits, handling loads in close proximity. GG Crane Group is to be complimented for innovative engineering and for persevering with a concept and bringing it to an official launch at Bauma 2010. Currently, the crane is offered in four models offering lift capacities up to 3,300 kg at jib end, and jib lengths of up to 2 x 85 m. Standard height on track is 60 m. Although we have some doubts on the potential for this product we look forward to reporting on an application in a country other than Belgium, where the crane is manufactured.

GG Crane Group

(exhibited by Yuasa Trading) Innovative asphalt finishers from Japan. Yuasa Trading has an established reputation for importing new and innovative products from Japan into the European market. Bauma 2010 saw the Hanta Crawler type mini asphalt finisher – the smallest paver of its type in the world the company believes. Designed for narrow, restricted areas, the mini-pavers are available in 2 models, the F14C-1.4 (2,900 kg) and F14C-1.8 (3,000 kg) for paving widths from 0.8 m to 1.8 m. Paving thickness ranges from 10 to 100 mm from a feed hopper delivering up to 53.6 m³/h. With the use of a reduction shoe, paving width can be reduced to as little 43 cm – ideal for cable trench renovations and rut filling. The fully hydrostatic drive system gives ease of control. The fully CE compliant models are powered by Kubota D1703-EU8, 1,647 cc engine delivering 17.3 kW/1,900 rpm. The compact size, minimum 720 mm width, makes it suitable for such applications as sewage and utility trench renovations,

Page 32 Contractors World Vol 1 No 5 a show of optimism

pedestrian path paving, rut patch and fill, and bicycle roads. They have proven their performance as axially pavers in even the German Autobahn repair works where the small size minimize disruption to traffic flow. With a paving width of 14 – 3.2 m, the prototype F1432C3 Zscreed from Hanta was also being shown. With a 2-step screed, the model offers paving thickness of 10-120 mm. It has a hopper capacity of 3,300 kg and a conveyor delivery capacity of 109 m³/h. Power is from a Kubota engine with rated output of 25.3 kW/1900 rpm.

Hanta / Yuasa Trading

(exhibited by Yuasa Trading)

Tracked dumpers find increasing opportunities Over recent years, rubber crawler dumpers have found an increasing acceptance as an efficient solution to carrying material around sites where ground conditions are not ideal for wheeled carriers. Yuasa Trading showed the Japanese models from Morooka. There are three models, the MST-1500VD, the MST-2200VD and the MST-3000VDS offering struck-load capacity from 2.73 m³ to 5.55 m³ and payloads from 6,300 kg to 15,000 kg. All are powered by a Cat diesel engine and have maximum travel speed of 8.5 km/h and ability to climb (empty )grades up to 57% (30º) Fully loaded, ground pressure on the largest model is a little as 0.48 kg/cm³. The smallest model is just 0.29 kg/cm³. A 60º tipping angle ensures smooth discharge of material. All models feature a fully enclosed cab for safety and comfort in all weather conditions.

Morooka / Yuasa Trading

The leading Japanese submersible pump manufacturer, Tsurumi, introduced in to the European market, the NK2-22 heavy-duty, high head, single phase submersible pump. Able to carry water over a total head of 25 m or reach flow capacities of more than 590 litres per minute, the pump is designed for tough working conditions. It features a synthetic rubber wear parts and a duct-iron material semi-vortex impellor for durability and consistent performance. The pump runs off a standard 220 v power supply. A high-flow model - the NK 2-22L will be available soon. Tsurumi Europe also announced that it has reached an agreement with Australian pump manufacturer, Primax Pumps - a division of the Sykes Group , to sell their range of automatic self-priming diesel pumps to Germany, France, Austria and Switzerland.

Tsurumi Europe

Primax Pump set from Australia to be marketing in parts of Europe by Tsurumi Europe.

Contractors World Vol 1 No 5 Page 33 a show of optimism

Formwork innovations from Doka It is always surprising to see how much further formwork and scaffolding companies can go in devising simpler, faster, more flexible solution to deliver higher-quality concrete finishes from what traditionally was a carpenter job using timber beams and plywood. Formwork systems are much different today and there are very few requirements for a skilled carpenter in modern formwork applications. Single-side tying system Doka had several interesting concepts at Bauma 2010. A good example of what I am talking about is their new Monotec tying system. Doka believe that this simple upgrade to existing formwork panels can reduce form-tying operations by as much as 25%. This is possible because the Monotec system enables formwork tying from one side only. It adapts steplessly to different wall thicknesses and fixing and removal is with an easy-to-use Monotec ratchet tool. Formwork tying can be done by just one person. Depending on the Doka systems being used, the Monotec can also double as a connecting device in place of a Quick- acting RU clamp. This can reduce the number of components required by up to 40%. Another development from Doka is a new I tec 20 The Monotec single-side tie can even be retrofitted formwork beam, which, compared to a conventional 20 cm right at the site, and shortens the form-tying operations high timber formwork beam, has a 80% higher load capacity by 25% without needing a big investment in a new but weighs the same. Key specifications are moment of 9 formwork system. kNm; shear force of 20 kN; a rigidity factor of 700 kNm² and weighing 5.8 kg/m. The benefits of this are self-evident meaning less material needed for any heavy-duty application. A further enhancement is a plastic strip along the flange to reduce splintering when nailed. This increases the life of the beam and contributes to lower formwork costs. This new beam is an integral part of the new large area formwork - Top 100 tec - making it possible to dispense with waling levels, reducing the number of wall ties ad labour costs by as much as 33%. The high-rigidity of the system means faster pouring while still ensuring a compliance with architectural finish specifications. Reducing infill zones Formwork costs can increase significantly if there are many infill areas. The new Dokadek 30 is a panel floor formwork that can be used for typical areas and for infill areas “in a record time” says Doka. The large 3 m² panels are used for the typical zone while rapid forming of the infill areas is with Dokaflex. This combination, within a single system can, according to Doka estimates, reduce forming time by 20%. More Innovations Doka looked at a solution to renovate cantilever parapets without inconvenience to road traffic. Their answer is the Forming wagon TU - a system that runs in a roller track fixed to the underside of the bridge superstructure making it possible to cast cantilever parapets without taking up any space on the bridge and without the need for any scaffolding.

The new Large-area formwork Top 100 tec is based on the high-load I tec 20 system beam.

Page 34 Contractors World Vol 1 No 5 a show of optimism

The Doka Forming wagon TU runs on the underside of the bridge and allows cantilevered parapets to be poured with zero disruption to traffic.

Made up of different modules, it can be quickly adapted to meet specific bridge parapet cross sections. Doka used Bauma to emphasise safety when working at height with the introduction of the Xsafe plus platform system - a pre-assembled work platform that folds flat and can be lifted into position in a single crane lift. The company also introduced the XP side-guard system - a universal safety system for all edge protection for all drop-off edges to help better retain components and tools on the decking.

Doka

Telehandler on tracks from Belgium It is not only the large, global manufacturers that get all the attention at Bauma. It is an opportunity for smaller, more specialised companies to show their innovative solutions and products.. A good example of this is marketed under the brand name Giraf Track by Testcentrumde Lille NV from Belgium. They manufacture what they claim to be ‘the only tracked telehandler’. It is available as the GT580B with standard base or the GT580-3C with driver cab. Both models can be operated by remote radio control. The model on show, the GT580B was equipped with VBlade option offer by Swiss rental company Airnace. It also featured a 13 m wide Ultra Large Basket for panel cladding applications. Based on Caterpillar excavator tracks and with a 16 m boom, the Giraf Track offers stability and all-terrain mobility - even when fully loaded. The 16,500 kg machine has a maximum lift capacity of 3.8 t., a maximum horizontal reach of 16 m and maximum working height with basket of 17.8 m although this can be increased to 20.8 m with basket on jib. Both models are powered by a Tier III compliant 4- cylinder diesel engine with rated output of 74.5 kW. For panel cladding or large area access, there is a 7 m wide platform which extends to 13 m. This has a payload capacity of 500 kg in addition to a 250 kg personnel capacity. Giraf-Track track-mounted access platforms/ Other options include independently rotating, telescopic telescopic handlers is an innovative concept from Belgium company, Testcentrum de Lille NV, in overhead lorry cane with 950 kg payload; pallet forks, Belgium. winches as well as specialised attachments for underbridge inspection, rail and highways applications such as anchoring.

Testcentrum de Lille NV

Contractors World Vol 1 No 5 Page 35 Held every 2 years, Hillhead has grown over the years and is today an important exhibition, with its working demonstrations. Here’s a preview of what to expect between June 22nd and 24th. Targeting the quarry and aggregate markets - Hillhead 2010 Held over from last year, when the organizers postponed the event due to the economic crisis and many exhibitors questioning the viability at a time of market uncertainty, there will still be some major companies missing from the event this year. However, that benefits the smaller companies who, all too often, do not get the attention they deserve. Hillhead 2010 has a mix of large, small companies offering a wide range of product. It is always an interesting event to visit. New products on show Along with other products, Powerscreen will officially The new Aggwash from Powerscreen to be officially launched launch the Powerscreen Aggwash at Hillhead - a new at Hillhead 2010 mobile wash plant which brings together for the first time rinsing, screening and scrubbing capabilities to a single, transportable chassis. Specifically designed for the processing of concrete and demolition waste or virgin material, the Aggwash produces 3 grades of aggregates and 1 grade of sand at a rate of up to 60 tph. The Aagwash is sized for small to medium sized quarries or contractors’ fleet. Liebherr-Great Britain Limited has a complete Mobilmix concrete mixing plant erected on the stand, together with three of the company’s concrete truck-mixers mounted onto the latest Mercedes Axor and Actros chassis. The Mobilmix 2.25 is a mobile horizontal plant which offers high outputs and, according to the company, features and capabilities which are equal to the production performance normally found on static plants. The plant features a Liebherr twin-shaft mixer with production capacities of up to 100 m³ ‘set’ concrete per hour. A microprocessor control, installed in its own integrated module, regulates and monitors the plant’s operation – moisture and temperature measuring devices are included, together with an admixture weigher. Targeting the serious aggregate produce is Sandvik with their new QE440 which has been developed and configured for the larger aggregate producers. It features 40% more screening area than its predecessor - the QE340. To better deal with both From Sandvik - the new QE440 which has the increased production capacity and facilitate larger stockpiles, been developed and configured for the larger the stockpiling conveyors are both wider, and higher. The QE440 aggregate producers comes complete with a more powerful, yet economical engine to maximise the productive capacity of the machine. Features includes a total scalping area of 5.5 x 1.75 m / 5 x 1.75 m and able to accept feed from large crushers. It is a fully tracked unit for on-site mobility and is compatible with other Sandvik supplementary equipment. Also taking the opportunity to show equipment working, CDE will be demonstrating their new M2500 mobile washing plant which “ . . is revolutionizing mobile washing” says CDE. Showing their ability to meet the dewatering, washing and other water handling capabilites is Pioneer Pump who will be exhibiting their latest range of high-efficiency, high capacity centrifugal pumps which can be packaged to suit specific customer requirements. Apart from providing pumps and after-sales support, Pioneer Pump also works closely with customers to devise the most cost efficient ‘total solution’ to minimise what is a necessary but non-profit contributing cost. [CW]

The PIONEER 80CX is yet another new pump benefiting from the innovative design process that the company delivers to produce pumps with exceptionally high performance

Page 36 Contractors World Vol 1 No 5 London 2012 Olympic Games Update

Already becoming established as a London landmark visible from many main routes in the east of London, the London 2012 Olympic Games main stadium and associated structures such as the aquatic centre and the velodrome with their distinct architectural designs, are progressing at an amazing rate. As this aerial picture and other pictures in the review show, work is progressing to schedule.

Second venue now completed The rowing and canoe sprint events during the 2012 Olympic and Paralympic Games will take place at the Eton College Rowing Centre at Dorney Lake near Windsor. Construction work has now been completed at the venue to provide improved facilities for athlete warm-up and canoe sprint events. The enhancement works include a new 50 m bridge at the finish line area, the upgrade of an existing gravel/stone access road within the venue site for use during the Games, and a cut-through and new bridge between the competition lake and return lane of the 2,000 m rowing course. Work starts on Olympic Stadium’s field of play On the second anniversary of the start of construction on the Olympic Stadium, work has begun on the field of play and the first batch of seats is being manufactured. The centre of the Stadium has been cleared of cranes and other equipment so work can begin on creating the correct ground conditions for the running track and the turf for the field events. Over the coming months, ducts and a drainage system will be installed and the base layers will be laid in preparation for laying the turf and track next year. The manufacture of the black and white seats has also started in a factory in Luton and they will start to be fitted into the Stadium later this summer. John Armitt, ODA Chair said: "The Olympic Stadium

Contractors World Vol 1Page 37 Aerial view of the white-water course under construction in the extended Olympic parklands at Broxbourne, to the north of London.

will be at the heart of the action in 2012 and its image will be beamed to billions of people across the world. “Only two years ago, the Stadium site was a flat piece of ground. A huge amount has been achieved since then with the venue now structurally complete and at its full height. Work is progressing on covering the roof and the first seats will be fitted this summer. The continuing progress means the Stadium is still on track to be completed a whole year before the 2012 Games.” Construction on the Olympic Stadium started in May 2008 and progress to date has included: • Over 4,500 reinforced concrete columns installed as the foundations • 12,000 pre-cast concrete terracing units for the seating installed • All five bridges and their abutments in place, connecting the Stadium island to the rest of the Park • Work has begun on the fit-out of the 700 rooms and spaces within the Stadium, including fitting toilets and tiling showers in the changing rooms • The 450 t cable net roof structure has been lifted into place • 14 lighting towers which sit 60 metres above the field of play have been lifted into place and the fitting of the power cables has started • 25% of the cable net roof has already been covered with a fabric material, which will provide the correct conditions for athletes on the field of play and cover two-thirds of spectators. • Landscaping work has begun including trees planted, a green wall installed. • The Stadium will contain around 10,000 t of steel making it the lightest Olympic Stadium constructed to date Athletes Village well advanced. The new homes and community facilities are taking shape in the Athletes’ Village, two-years since construction work began. The Athletes’ Village, which lies adjacent to the Olympic Park, will accommodate athletes and officials during the Olympic and Paralympic Games. After the Games the Village will deliver the legacy of 2,818 new homes for east London, of which 1,379 will be affordable, owned and managed by Triathlon Homes. The new homes will be built across 11 residential plots and will be joined by new parks and open spaces. Construction work started on the Athletes’ Village in June 2008 and three-quarters of the residential plots in the Village are now structurally complete. The structure of the world-class new education campus being built in the Village, Chobham Academy, is coming out of the ground with the second floor of the four storey building now structurally complete. Earthworks are also now underway on the site of the state-of-the-art new Polyclinic in the Village that will provide healthcare facilities for existing local communities and the new residents that will live in the Village after 2012. The structures of all 11 residential plots in the Village will be completed later in the summer, with the external cladding works well underway and the internal fit-out of the buildings starting. The Athletes’ Village is due for completion in early 2012. [CW]

Page 38 Contractors World Vol 1 No 5 Spreading the light around the word - for the benefit of all. A word of encouragement to Latest newsletter Overseas branches - Don Baldry In the early days of the Lighthouse Club, back in the no street lighting ‘50s, (whence came our name - St. Mary’s Light, Whitley Bay gave our somewhat mellow founders Read latest their illumination) the main purpose of the Club was networking. That purpose was International underlined by our declared aim: The furtherance of Good Fellowship among Liaison Report construction people. June 2010 As we know, the Club developed very rapidly, branches were formed throughout the U.K. and Ireland and in 1962 the Lighthouse Club Benevolent Fund received official charitable status. And the Club began to spread it’s wings, in those times via BOAC and their Comet jet flights to the far east. Although our Lighthouse was adopted in the Netherlands very early on, theirs is a somewhat elite organisation. The first mirror image of our U.K. set up was formed in Hong Kong by the expat community, they too combined networking and charity. Now, more than twenty five years later, Hong Kong, with over 1,000 members and a very active benevolent fund, is the hub for our ten branches in the Asia/Pacific region and maintains close links with branches in Abu Dhabi and Dubai. In all there are well over 4,000 members in these far flung centres of ‘Good fellowship’. Most of these branches organise monthly get-togethers, and for any member newly arrived in the locality these are a very useful source of friendship and local contacts. Monthly get-togethers are generally well attended, not surprising since, for instance, one venue in Kuala Lumpur was voted ‘Best Pub in Malaysia’ and the Dubai Offshore Sailing Club can’t be a bad destination for a night out! There are, of course, much grander events. Earlier this year, Hong Kong’s International Gathering brought together 200 members from Asia/Pacific, the Gulf and U.K. all of whom enjoyed a great evening which raised HK$25,000 for their Benevolent Fund. Hong Kong, Saigon; Abu Dhabi, Kuala Lumpur; five decades on the friendship, fellowship and common interests of our Club’s founders that continue to enjoy wherever our lighthouse shines. It’s a brilliant light. See overseas branches here

As the publisher of CONTRACTORS WORLD magazines, Roger Lindley is pleased to promote the aims, objectives and benefits of the Lighthouse Club around the world. Travelling around the world for over 30 years, I have been privileged to visit many job sites of every description. I also came to appreciate the camaraderie that makes being away from home more bearable - in my case just a few weeks. For many in the industry, many years. The construction industry worldwide is like one big club - people move from project to project, contractor to contractor The membership does not change, just the business card. This is why the Lighthouse Club can be a unifying organisation enabling like-minded people to get together and share experiences, while helping raise vitally needed funds for those locally who suffer hardship as a result an accident in the construction industry.

Support the Lighthouse Club - become or member or help by making a donation. Do it now.

Read the current Lighthouse Club Newsletter on-line now

Promote your company by sponsoring a tree in our virtual forest - all proceeds to the Lighthouse Club

Lighthouse Club

Contractors World Vol 1 No 5 Page 39 COMPANIES FEATURED

in this issue of Contractors World Vol 1 No 5

Case Lieca Caterpillar Lighthouse Club CDE Group Manitowoc Doka Morooka Dynapac Murray & Roberts GG Crane Group New Holland Giraf Track Peri Hamm AG Pioneer Pump Hanta Powerscreen Haulotte Sandvik JCB Testcentrum de Lille NV Joseph Vögele AG Tsurumi Pumps Kleemann Wirtgen Group Komatsu Wirtgen GmbH Liebherr Yuasa Trading

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