Customer: Zementwerk LEUBE GmbH
Construction period: 11.2009 – 03.2010
Location: Gartenau/St. Leonhard, Salzburg
Country: Austria

At the core of the modernization of the cement production was the construction of a more than 100 metre high heat exchanger tower – about 30 metres higher than the existing plant. The tower measures more than 100 m from its lowest edge to the highest concrete edge. Four envelopes without false ceilings have been constructed with the self-climbing scaffolding SKE 100 at the top 90 metres. The four walls have been constructed with a width of 40 cm. However, at roughly every 11 metres, the profile was widened for two metres to 80 cm. This required the formwork to be reconstructed repeatedly. Only an additional six months have been allocated for the construction (steel construction, plant construction, etc.) for this large-scale project. The tower was constructed by the ALPINE crew, Department Industrial Construction Salzburg, in 3 to 5 shifts (working hours 0 to 24 o’clock) in a record-breaking 3 day cycle. In the new heat exchanger tower the waste heat from the oven now pre-heats the rock meal up to 1,100 °C instead of the previous 800 °C. Subsequently, it is burned to cement clinker at 1,450 °C in the rotary furnace. The improved use of waste heat saves about 8,000 tons of coal every year, an amount equivalent to the average heat consumption of about 2,500 single family houses. Additionally, 320 deliveries by truck will no longer be needed, resulting in less noise emissions for neighbours. The new plant reduces the annual CO2 emission by 30,000 tons and also reduces the emission of nitric oxide.

Construction features:
Hydraulic self-climbing scaffolding, highest possible safety at work / inside and outside wind guard on all 4 scaffolding levels, thermal insulation of formwork / winter construction site and panoramic 90-m-high elevator for construction site personnel.

Technical Data
Height of building: 105.55 m (from – 7.50 m up to + 97.05 m)
Concrete usage: 5,000 m³
Armouring usage: 650 tons
Formwork for foundation: 200 m²
Formwork for floor slab: 1,275 m²
Formwork for walls: 12,200 m²
Man-hours: 18,000

Special features
The tallest crane in Austria and at the same time one of the tallest in all of Europe was used during construction