What is Truck Concrete Spray Pump
A truck equipped with a concrete mixer is also known as transmixer or agicar. In underground mining, due to the small-section galleries and harsh conditions of the terrain, low-profile truck mixers with compact dimensions and powerful engines are used, which allow good maneuverability and mobility. The truck mixer's role in underground mining is transporting the shotcrete mix to the spraying area. The need for equipment quantities varies depending on the traveling distances and logistics of the mine.
Advantages of Truck Concrete Spray Pump
Pumping pipes can reach places that are difficult for people to reach
When using a wheelbarrow to transport concrete before, there were many places that the wheelbarrow could not reach, such as high-rise buildings. Now, the pumping pipes of the concrete pump can reach places that are difficult for people to reach. It can pump not only horizontally over long distances, but also vertically.
Moreover, two concrete pumps can also be used in series to increase the conveying distance and height to meet various construction requirements.
In addition, after the pumping pipe is laid, if necessary, workers can move the pumping pipe to any position, which is convenient and fast.
High degree of mechanization and high pumping efficiency
During the construction process, the conveying and pouring of concrete is continuous, so the concrete pump can work continuously, improving the pumping speed and construction efficiency.
Moreover, since the concrete pump and other construction equipment do not interfere with each other, other construction operations can be carried out near the pipelines while pumping, which greatly improves the construction progress and shortens the construction period.
Save manpower and reduce labor intensity
The concrete pump has a high degree of automation. Except for laying pipes, other operations can be completed by only three to five people, which reduces labor intensity and saves labor cost.
In addition, the concrete boom pump does not need to lay the pipe manually, but only needs the operator to press the corresponding control button to finish laying the pipe automatically.
Finish the projects quickly
Due to the high working efficiency of the concrete pump, it can help customers to complete the project faster. And after a project is over, the concrete pump can be quickly moved to another construction site, reducing the time required for transfer.
The concrete boom pump and cpncrete line pump truck have their own chassis, which is easy to move. The trailer pump and concrete mixing pump also have wheels, and only need to be towed by a trailer when transferring.
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Truck Mounted Concrete Wet Spraying Machine
With the continuous innovation of tunnel construction technology, more and more new technologies
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Our Factory
Taian Minle Machine Manufacture Co., Ltd. is mainly engaged in the production, research and development, and sales of concrete construction equipment, concrete shotcrete robot equipment, concrete mixer with pumps and so on.
Our Product
The company's main products are concrete pumps, pumping concrete mixers, concrete pump trucks, etc., which have been widely used in many construction engineering fields such as residential buildings, railways, water conservancy, construction tunnels, underground coal mines, and national defense.
Our Certificate
All products have passed BV and ISO9001 international quality system certification, and the coal mine concrete pump has passed the mining product safety approval certificate.
Rich Experience
Our rich experience and our good after-sale service will make a win-win business relationship with you! We value our customers and we supply you with the best solution for your construction works.
Operators and associated equipment management staff should familiarise themselves with the concrete pump's structural principles, usage, and maintenance, as well as any other pertinent information, before operating the pump. It is recommended to use the instruction handbook at random since the operator has a good knowledge of the mechanical performance requirements. Also, to make sure that some pumping technology variables, such as pump placement and pipe architecture, are well-controlled, it's important to follow the instruction handbook while formulating particular operating points.
It is imperative that the concrete pump be set up on solid, level ground and that the entire apparatus not be slanted in any way while in operation. The outriggers must be securely fastened or locked in place so that the entire machine may be supported stably. Because of its proximity to the concrete mixer truck and the hopper, as well as its ability to pump the cloth pipe and minimise pumping pressure loss, the pump's placement should be carefully considered. Convenient access to water and electricity, as well as proximity to the pouring site, are also necessary.
The specifics of the building site and the preparation schedule for pouring concrete should guide the piping work. Before you start designing the pipes, make sure the concrete pump's pumping distance and the pipeline's horizontal conversion distance are suitable. Pipes should be as short as possible, and hoses and elbows should be used sparingly during plumbing. The conveyancing pipe should be laid in a way that makes it easy to clean, diagnose, disassemble, and maintain. During the process of mixing the new pipe with the old pipe, the new pipe ought to be positioned in such a way that the pumping pressure is elevated. While plumbing, it's important to make a detailed inventory of all the pipe fittings, clamps, elbows, and hoses, as well as their measurements and amounts.
When piping needs to be raised upwards, there is a propensity for concrete to flow backwards as the height increases, which might be seen as an increase in potential energy. As a result, to make sure the concrete has enough resistance, a specific length of horizontal pipe should be placed between the vertical pipes and the concrete pump. Reverse flow. Pipes must be installed vertically upwards in order to pump concrete for tall buildings. Right now, the horizontal pipe length on the ground shouldn't be shorter than a quarter of the pipe length in the vertical orientation. If the water pipes that are needed are too long to be installed on the site, shorter pipes or hoses might be utilised in their place.
While pumping concrete, the impact force of the pump causes the pipe to oscillate back and forth, causing the pressure to drop and potentially damaging the connection between the pipes. It is necessary to repair the pump since the tensioned state might result in early damage to the pipe clamp and the rubber ring, as well as an overflow of cement slurry.
Before turning on the concrete pump for dry operation, make sure it passes a thorough check according to the specifications in the operating manual. This should be done after connecting it to the delivery pipe. Verify the correct operation of every system and mechanism after operating without load for 10 minutes.
To avoid blocking the concrete conveying pipe from the fast loss of slump caused by direct sunshine, it is recommended to cover it with wet straw bags, wet cover cloth, etc., when construction is being done during the hot season.
Proper thermal insulation measures, including the use of thermal insulation materials to encase the concrete delivery pipe, are necessary for wintertime concrete pumping construction in extremely cold regions to avoid freezing the concrete within.
Truck mixers have two functions: mixing and agitating, and their application depends on the type of concrete plant that the jobsite is using.
If the batching plant includes a concrete mixer, the truck mixer only needs to agitate the shotcrete mix so that it does not disaggregate during transport to the spraying area.
If a dosing plant is used, the truck mixer also has to mix the shotcrete while loading, and then agitate the mix during transport.
Mixing the shotcrete should only be done while the truck is stopped, otherwise there is a risk of overturning. During transport, the mix should only be agitated. Agitating requires a lower rotation speed of the concrete drum than mixing.
Working cycle of the truck mixer: Loading, transporting, and unloading
A truck mixer's work consists of picking up the shotcrete mix from the concrete plant or line, transporting it to the spraying area and unloading it to the concrete spraying equipment.
Putzmeister recommends that during the whole cycle you do not exceed 300 rotations in total in order to conserve the properties of the shotcrete mix.
While loading the concrete, use the appropriate rotations per minute according to the function that is being carried out. For agitating, a range from 2 to 6 rpm is sufficient. For mixing, the concrete drum must turn faster, with a maximum of 12 to 18 rpm.
Transporting the mix from the concrete plant to spraying area must only be done at the proper rotation speed. Continuous excess speed causes the shotcrete mix to lose its workability; therefore, it is recommended to lower rpm during transport.
When unloading, adjust the rotation speed to the flow rate of the concrete pumping equipment.
So as not to exceed the 300 rotations recommended during the complete loading, transport, and unloading cycle, you should calculate the rpm used during loading and transport so that the available margin required for unloading the mixture can be adjusted to the pump flow.
Regular Concrete Pumping Versus Shotcrete Pumping
Regular concrete pumping
Firstly: Regular pouring or pumping, which you normally use for foundations, slabs, high-rise buildings and bridges. In fact, any application that might require bigger rock or aggregate and a higher output volume of concrete.
For this kind of material, you need to use a specific kind of concrete pump. In most cases you would use an s tube or a rock valve system. This is an oscillating delivery tube which changes position between two material cylinders. Back in the day, there was also a gate valve system. This consisted of a metallic gate or trap that would alternate an opening in front of the two material cylinders.
Shotcrete pumping
The second kind of material that can be pumped is called shotcrete.
This material is very fluid but dense, and has either a very small aggregate of less than half an inch or no aggregate at all. You normally use Shotcrete to fill foundations, create swimming pool walls, or any other applications that might require high-pressure delivery.
For placing this more dense concrete material, there is a specific concrete pump with either a ball valve delivery system, or the regular valve delivery, but with shorter cylinders, to increase the frequency in which the pistons move, delivering less volume at higher speeds. The ball valve consists of 2 metal balls in a box with 2 chambers. The 2 balls are in front of the material cylinders and below the feeding hopper.
Every time a material cylinder pushes material through, the ball in front of it gets pushed up, plugging the hole to the feeding hopper and preventing the material from returning to the hopper. At the same time, the other material cylinder is suctioning, causing the second ball in the chamber to drop, allowing concrete to move from the feeding hopper to the material cylinders.
These concrete pumps for looser concrete normally work under high pressures. The ones that use a ball system, the wear is less than a conventional pump. We always recommend using a ball valve for shotcrete pump instead of an “S” tube or rock valve. This is because there is a higher wear on the oscillating parts of these two systems, and it may return grout to the feeding hopper. This causes delays on the job and, because of the high pressure, damages the differential cylinders.
Regular concrete pumping, only requires the pump and concrete pump hoses to complete delivery of the material.
Shotcrete pumping on the other hand has to be done with an air compressor. Basically, this is a very thick mixture normally 4500 PSI or more of resistance on the concrete and it is normally applied at a 4-inch slump therefore making it kind of volatile because if you plug, you don't have too much time to unplug. Normally, it doesn't carry too much rock. It doesn't carry big rock in it, and mostly it is used for shooting walls or covering surfaces that have damages to them.
Shotcrete pumping is normally done by either the ball valves mentioned above or there are other kinds that are using a special differential cylinders with reinforced end cups. Because what happens is: If you use a regular concrete pump to do shotcrete pumping, which is much higher pressure, you will eventually damage the differential cylinders. So these specially designed shotcrete pumps basically give you a higher rate of shifting from cylinder to cylinder keeping a constant pressure against the differential cylinders and those differential cylinders and cups are reinforced so they don't come off as a regular concrete pump would.
Normally you use a shotcrete nozzle that has on one end, the connection for the 2-inch concrete pump hoses, and in the other end you will have the connection for the air hoses. You combine those two in an enclosed nozzle, Which will allow you to control the flow of delivery. Basically concrete shoots out of the nozzle chamber at a high speed.
It is very convenient when building structures that have been pre-made or pre-casted.
The Risks of Working with Concrete Pumps
Pipeline failure
When operating, the hopper and pump are under high pressure. Any weakened pipe is at extreme risk of failing during peak pump pressure.
If pipeline failure occurs, workers could be struck with rock projectiles, hygroscopic concrete slurry, or other debris - resulting in serious injury. Additionally, wet concrete would be spread around the ground causing slips, falls, and hazardous conditions.
Equipment & employee downtime
It's no surprise concrete pumps should be regularly maintained for proper performance. However, it's important to remember: While pump maintenance reduces the risks of major breaks, it's not an absolute guarantee.
In the unfortunate event of pump failure, not only are your employees potentially in danger, they may be temporarily out of work while it's being fixed. This interruption not only affects productivity, but also has consequences on your reputation, time management, and profit.
Pump operator mistakes
Skilled operators understand how much hose to use during the job as well as the perfect concrete mix. If someone isn't fully trained, any error could create tears, kinks, or ruptures mid-operation.
Additionally, trained operators are able to notice abnormal changes. If the concrete is being pumped too rapidly, the pressure can spike and potentially result in a pump failure. Skilled operators should know to reverse the pump a few times before forwarding it to reduce the chance of pump failure or blockages.
Pump blockages
Blockages can be a result of a poor mixture. If the mixture doesn't capture enough water, blockages are nearly guaranteed to occur.
Pump blockages can have the same impact as a weakened pipe – the blockage can cause a build-up in pressure, resulting in a release such as concrete slurry or debris ejecting from the pump and injuring workers around.
How to Maintain the Hydraulic System of Concrete Pump Truck
The hydraulic system is the essential of concrete pump truck, because of it's the power source of boom ,main cylinder，etc. Once the problem appeared in hydraulic system,it can probably lead to some of the program can not be done, which is generally we say hydraulic failure. Therefore,the hydraulic system maintenance is very important, And the hydraulic oil as the transmission medium is also very important in the entire hydraulic system.
Hydraulic system daily inspection & maintenance
- Daily check whether the hydraulic oil is emulsified. Generally, it is caused by water infiltrated into the hydraulic oil, which requires you to drain the oil tank regularly(Probably once every 60 hours while the pump truck didn't work ).
- Check the oil gauge of the pump truck to ensure that the hydraulic oil level cannot be lower than the minimum working liquid level during normal operation, and it must be added immediately when it possible below the liquid level.
- Check if the cooling system of the pump truck is working properly.
- Check for hydraulic leaks in the hydraulic lines.
- Mixing system and transfer case are prone to hydraulic oil leakage,Generally, the water enters the hydraulic oil of the mixing system and part of the oil in the transfer case enters the hydraulic system. Therefore, if any oil leakage is found in the mixing system, please replace the seal in time.
Maintenance time of hydraulic system
Generally, pump trucks that work normally need to be update Hydraulic oil once every six months.While the entire vehicle hydraulic oil be replaced and also the filter element needs to be updated.Both the main oil tank and the boom oil tank need to be drained. It is best to thoroughly clean the fuel tank once. There may be some metal solid residue at the bottom of the fuel tank, which needs to be glued out with.
Many turck owners usually do not pay attention to the maintenance of the hydraulic system of the pump truck. The hydraulic oil may only be replaced once a year or two, and the oil may have become black. In this way, it is easy to damage the hydraulic valve, hydraulic pump and other parts like.However, the maintenance cost of these components is not cheap, so the normal maintenance of the equipment is very necessary.
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