The Main Components of a Concrete Pump

Posted On: 05/31/ | Posted by: DY Concrete Pumps

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Understanding common concrete pump parts is an essential part of pumping concrete. Each component is essential to the process, allowing contractors to complete jobs safely and efficiently. Control circuits, spraying arms, air compressors, pipe systems, hoses, cleaning components, clamps and gaskets work together to help you finish projects and maintain your reputation.

The Importance of High-Quality Concrete Pump Parts

Construction is changing worldwide &#; urbanization has increased rapidly in recent years, meaning the need for efficient, practical construction is also rising. As ready-mixed concrete becomes more accessible, its many advantages will increase demand.

Construction requires efficiency. High work standards, increased project productivity and the ability to pump concrete into hard-to-reach places are crucial. A concrete pump and its components allow for faster and more consistent concrete distribution. Each of a concrete pump&#;s essential components leads to quality projects and repeat customers.

High-quality concrete pump parts are fundamental for operations. Using quality parts helps you complete jobs safely, effectively and efficiently.

The Working Principle of a Concrete Pump

Concrete pumps efficiently transfer fresh-mixed concrete to desired locations using hydraulics and a valve system. The mixed concrete moves into a hopper, which continues the churning process to prevent solidification. The concrete pump sucks the liquid concrete out of the hopper using a valve system, then transfers it to where it needs to be.

A typical concrete pump contains twin hydraulic cylinders that work in tandem, pushing and pulling the concrete. The continual hydraulic concrete flow causes the cylinders to alternate back and forth and plays a vital role in preventing premature concrete solidification.

What Are Common Concrete Pump Parts?

A concrete pump has many components, and each is vital in pumping concrete effectively. Consider the following essential parts of concrete pumps.

1. The Main Pump Circuit

The primary pump circuit is one of a concrete boom pump&#;s most crucial parts. This circuit controls the parallel hydraulic drive cylinders and features the following components.

• Piston pump: The main hydraulic power pump gets its power from a variable displacement axial piston pump complete with a swashplate design. Adjusting the swashplate angle changes the stroke length of the pistons, and this process changes the concrete displacement. The more flow, the larger the swashplate angle becomes. Operators can adjust the swashplate angle using the load sense feature and the volume control.
• Motor: An engine or electric motor powers the main hydraulic pump. When the engine operates like usual, the pump switches off, minimizing the pressure on the pump and providing enough power to keep the pump lubricated.
• Valve manifold: A valve on the main circuit controls flow, the relief valve, the check valve and the pilot-operated directional valve.
• Throttle control: To energize the pump circuit, the operator sets the speed to maximum RPM using the throttle control.
• Cycling circuit: Once the pump switches on, it immediately triggers the cycling circuit. This circuit generates an electrical signal and activates the directional valves.
• Material cylinders: The two parallel cylinders alternately pump the concrete. Proximity sensors trigger the material pumping action, sending the signal from the sensors to the logic controller.
• Relief valve: This valve protects the primary pump circuit from extreme pressure. When the system pressure reaches the maximum allowed, the relief valve opens to let oil return to the tank.

2. The S-Tube Shift Circuit

This circuit controls the function for shifting the S-tube from one cylinder to the other during pumping. As there&#;s a single outlet for pumping material, there must be a method to transfer concrete from the cylinder to the outlet and then onto the delivery line.

The hopper has an S-tube to ensure task completion. There&#;s one S-tube for two cylinders, so it must be easy to shift from one cylinder to another. We can explain this circuit by considering each of the following components.

• Tandem pump: To meet pressure and flow requirements, a tandem pump installed in a single section of the shift circuit connects to the main hydraulic pump, which drives it.
• Manifold block: Just like the main hydraulic circuit, there are manifold blocks in the shift circuit.

3. The Auxiliary Circuit

The agitator&#;s hydraulic function is part of the auxiliary unit. The circuit controls the operation of the agitator and other additional equipment.

The agitator rotates to mix the concrete in the hopper and feed the cylinders. The tandem pump on the main circuit serves the auxiliary circuit. A solenoid cartridge or dump valve is a safety mechanism to prevent flow to the auxiliary circuit when the operator activates the emergency stop circuit.

One of the most significant functions of the auxiliary circuit is to assist in pumping concrete high in the air and over long distances. The main components of this system include the following.

• Elbow with wear-detecting holes: These holes in the concrete pump elbows consist of quench casting material. They smooth the ready-mixed concrete flow and increase safety and durability.
• Outrigger: This component hangs at an oblique angle and widens the overhanging area for more significant stable movement.
• U-shaped bottom of the hopper: This part facilitates the initial movement of the liquid concrete from the hopper into the intake port. Cleaning is more accessible due to the efficient flow of the ready-mixed concrete, as it reduces the remaining volume.
• Power-operated vacuum pump: This battery-powered vacuum pump minimizes pulsation and discontinuity in concrete flow. This component creates a more homogeneous mixture.

4. The Spraying Arm

The spraying arm positions the concrete flow at the correct location. Telescopic elevation platforms and scaffolding are unnecessary, as the component can spray for distances up to 56 feet. The spraying head mixes concrete, elevators and air. The nozzle dimensions and overall design are vital for ensuring minimal rebound and correctly incorporating the concrete.

5. The Air Compressor

The air compressor gives the concrete the kinetic energy to spray and compact. A specific velocity is necessary for shotcrete to impact the site&#;s surface, achieved with the compressor&#;s airflow and the correct nozzle diameter.

6. The Additive Pump

The accelerator meets the requirement for early strength development by speeding up the hardening of the concrete. The dosage depends on the concrete flow at all times. A synchronized dosing device, combined with the concrete pump, performs this function.

7. The Motorized Chassis

The motorized chassis transports the concrete pump to the desired location. The chassis design is crucial, as it needs to be able to turn in relatively small spaces and operate on uneven terrain.

8. The Control Panel and Remote Control

The control panel allows for ease of operation and confirms the condition of the ready-mixed concrete inside the hopper. Operators can control the pumping speed based on the operation&#;s needs. The digital display indicates when to perform maintenance checks or replacements.

Operators can use a remote control to manage the spraying process on site. Remote controls can be wireless or work via a cable connection and organize all the concrete components from one convenient location.

Additional Concrete Pump Parts

The following additional parts are also essential for proper concrete pumping.

Pipe Systems

Concrete pipes help contractors process concrete for projects, transfer it to work sites and deliver it to facilities safely and efficiently. Twin wall pipes are durable and specially designed for heavy-duty jobs. A twin wall pipe features a steel outer wall and a resistant inner lining that prevents corrosion and hardening. These features protect concrete and prevent it from hardening, allowing it to flow properly during distribution.

Hoses

Concrete pump hoses pump thick and abrasive substances such as concrete. A pump hose is durable and uses high pressure to pump concrete efficiently and safely. Their durability resists corrosion so you can complete jobs without inflicting damage.

Clean-Out Balls and Ball Catchers

Sponge foam clean-out balls are also important cleaning components because they help clear residue from the inside of pipes and hoses. After pumping concrete, you can use clean-out balls to clear debris, residue and remaining cement from the inside of concrete pump hoses. Clean-out balls have a parting stretch that enables them to move through narrow spaces without sustaining damage.

You also need a ball catcher when cleaning pipes. A pump pipeline might propel a clean-out ball, and you need something to stop it from flying across a work site. Remove the pump hose before securing the catcher and ensure the ball catcher fits the pipeline precisely.

Clamps and Gaskets

Concrete pump clamps connect and secure hoses to concrete pump boom pipes. Always use a pump clamp with a gasket to seal a hose and boom pipe connection.

Hose Pans

A hose pan reduces friction during pumping. Hoses can form bare patches when they surge forward and backward on the ground, but hose pans reduce friction to help the outer surfaces of hoses remain intact and last longer.

Safety Straps

Fit a concrete pump hose with a safety strap to keep it lifted and prevent it from falling. Ensure safety straps are in good condition to prevent them from malfunctioning or breaking. Purchase new durable safety straps if you notice your current straps are worn or damaged.

Reducers

A reducer is a pipe that can adjust to a smaller size. Reducers connect larger-diameter pipes to smaller-diameter pipes, which lessens flow. Using a high-quality reducer can help you achieve a steady stream for concrete pumping.

Contact DY Concrete Pumps Inc. for Your Next Concrete Pump

Using high-quality concrete pump parts helps your pump operate efficiently and increases its longevity.

If you want to increase your on-site efficiency or upgrade your concrete pump, DY Concrete Pumps Inc. can provide you with all the information you need to make the best choice for your business. Whether you&#;re looking for concrete boom pumps or line pumps, our extensive inventory has the ideal concrete pump to suit your operational needs.

As leading manufacturers in the industry with over three decades of experience, we can help you provide innovative and effective solutions for your clients. Contact us to learn more and upgrade your equipment today.

Machine used for transferring liquid concrete by pumping

Because it is a fluid, concrete can be pumped to where it is needed. Here, a concrete transport truck is feeding concrete to a concrete pumper, which is pumping it to where a slab is being poured. Pumping concrete into aluminium concrete formwork in Mexico.

A concrete pump is a machine used for transferring liquid concrete by pumping. There are different types of concrete pumps.

A common type of concrete pump for large scale construction projects is known as a boom concrete pump, because it uses a remote-controlled articulating robotic arm (called a boom) to place concrete accurately. It is attached to a truck or a semi-trailer. Boom pumps are capable of pumping at very high volumes and are less labor intensive to operate when compared to line or other types of concrete pumps.

The second main type of concrete pump, commonly referred to as a "line pump" or trailer-mounted concrete pump, is either mounted on a truck or placed on a trailer. This pump requires steel or flexible concrete placing hoses to be manually attached to the outlet of the machine and feed the concrete to the place of application. The length of the hoses varies, typical hose lengths are 3.0, 3.8, 7.6, and 15.2 metres (10, 12.5, 25, and 50 ft), depending on the diameter. Due to their lower pump volume, line pumps are used for smaller volume concrete placing applications such as swimming pools, sidewalks, single family home concrete slabs and most ground slabs.

There are also skid mounted and rail mounted concrete pumps, but these are uncommon and only used on specialized jobsites such as mines and tunnels.

History

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Until the early 20th century, concrete was mixed on the job site and transported from the cement mixer to the formwork, either in wheelbarrows or in buckets lifted by cranes. This required a lot of time and labor. In , the German engineers Max Giese and Fritz Hull came upon the idea of pumping concrete through pipes. They pumped concrete to a height of 38 meters (125 ft) and a distance of 120 meters (130 yd). Shortly after, a concrete pump was patented in Holland in by Jacob Cornelius Kweimn (Jacobus Cornelius Kooijman). This patent incorporated the developer's previous German patent.[1]

Mechanism

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Concrete pump designers face many challenges because concrete is heavy, viscous, abrasive, contains pieces of hard rock, and solidifies if not kept moving.

Operating principle of piston pump with seat valves

Usually, piston pumps are used, because they can produce hundreds of atmospheres of pressure. Such piston-style pumps can push cylinders of heterogenous concrete mixes (aggregate + cement).[2] At present, double-piston pumps are predominantly used, which are hydraulically driven by electric or diesel engines using oil pumps.[3] The pressure pistons are hydraulically connected to each other through the drive cylinders and operate in a two-stroke mode.

For lower pressures peristaltic pumps are common.

How it works

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The return pressure piston of one pressure cylinder creates a vacuum, the medium from the feed funnel is sucked into the cylinder. At the same time, the advancing delivery piston pushes the contents of the other delivery cylinder through the transfer tube into the delivery line. At the end of the stroke, the pump switches, i.e., the transfer tube turns in front of the other filled pressure cylinders, and the pressure pistons change their movement direction.[4]

Concrete pump drives are now exclusively hydraulic, so control options vary between individual manufacturers. Each system has certain advantages and disadvantages.[5]

Important performance factors are:

• discharge pressure

• machine weight

• price

• system complexity

For these reasons, many options have existed side by side for a long time. Nowadays, fluid pressures of up to 400 bar (5,800 psi) and flow rates of up to 200 m3/h (260 cu yd/h) can be achieved, while using piston-type pumps.

Example of pump performance

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To illustrate, below are data on a typical concrete sample pump BRF 42.14 H:

BRF 42.14 H pump

• Vertical reach of boom: 41.9 meters (137 ft)
• Horizontal reach of boom: 38.0 meters (124.7 ft)
• Pumping rate: 30 m3/h (39 cu yd/h)
• Concrete pressure: 112 bar (11,200 kPa; 1,624 psi)
• Cylinder length: 2,100 mm (83 in)
• Cylinder diameter: 210 mm (8.3 in)
• Number of substitutions of strokes per minute: 27
• Number of outriggers legs: 4

Gallery

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• Construction site with concrete pump

• A Putzmeister concrete pump in Germany in

• Concrete pump folded for transport

• Boom concrete pump

• Concrete pump

• Putzmeister brand positive displacement mortar and plaster pump

• Photo showing a concrete pump working a large foundation pour, showing deployed outriggers, rebar mats, and concrete mixer delivering concrete.

• Fully deployed concrete pump, showing outriggers and boom in use while receiving concrete.

See also

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References

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