How to choose a high-quality pump truck
The pump truck is an important equipment for transporting concrete to the construction site. It can improve construction efficiency, reduce labor costs, and ensure the quality of concrete. However, there are many brands of pump trucks on the market, and the quality is uneven. How to choose a high-quality pump truck? This article will provide you with some reference suggestions from the following aspects.
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1. The type and purpose of the pump truck. According to the way of pumping concrete, pump trucks can be divided into car pumps, trailer pumps, truck pumps and tower pumps. Different types of pump trucks are suitable for different engineering occasions. For example, automobile pumps are suitable for large-scale projects such as urban construction, bridges and tunnels, and trailer pumps are suitable for rural construction and small-scale projects. Therefore, when choosing a pump truck, you must choose the appropriate type and specification according to your own engineering needs.
2. The performance and parameters of the pump truck. The performance and parameters of the pump truck directly affect its working efficiency and safety. When choosing a pump truck, pay attention to the following important parameters: maximum conveying capacity, maximum conveying distance, maximum conveying pressure, maximum conveying height, maximum conveying particle size, etc. These parameters determine whether the pump truck can meet the concrete delivery needs of the project, and whether it can ensure the uniformity and stability of the concrete. Generally speaking, the higher the performance of the pump truck, the higher the price, so you should choose a pump truck with reasonable cost performance according to your budget and actual situation.
3. The brand and quality of the pump truck. Brand is an important symbol to measure the quality of pump trucks. Generally speaking, pump trucks of well-known brands have high guarantees in terms of technical level, production technology, and after-sales service. When choosing a pump truck, try to choose a brand with a good reputation and reputation, and avoid buying fake or inferior products. In addition, pay attention to check whether the various parts of the pump truck are intact, whether there are corrosion, cracks, oil leakage, etc., whether there are qualification certificates and inspection reports, etc.
4. Use and maintenance of pump trucks. During the use of the pump truck, it is necessary to abide by the operating procedures, and carry out regular cleaning, lubrication, overhaul and other maintenance work to prolong its service life and ensure its normal operation. When using the pump truck, pay attention to the following points: (1) Before starting work, preheat and test run the pump truck to check whether all components are normal. (2) When transporting concrete, it is necessary to control the concentration, temperature, moisture content and other indicators of the concrete to avoid failures such as pipe blockage and flow failure. (3) After the work is finished, the pipes and hoppers should be cleaned in time to prevent the concrete from agglomerating or hardening. (4) When parking the pump truck, choose a flat, dry and ventilated place to avoid direct sunlight or rain.
In short, when choosing a high-quality pump truck, it is necessary to comprehensively consider its type, performance, brand, quality, use and maintenance, etc., and make a reasonable choice according to its own engineering needs and actual conditions. I hope this article can be helpful to you. If you have other questions or needs, please contact us and we will serve you wholeheartedly.
HOW DOES A CONCRETE PUMP WORK?
HOW DOES A CONCRETE PUMP WORK?
Construction is a booming business and one whose demands are expected to increase in the coming years. According to the World Economic Forum, the population of the world’s urban areas is growing by 200,000 people a day, and all those new inhabitants need housing, medical services, schools, transportation infrastructure and more. Construction of urban infrastructure to meet the needs of a growing population will almost certainly keep construction contractors and laborers in high demand in the coming years.
In the construction business, efficiency and reliability are at a premium. But on many projects, especially large, complex projects, it’s easy to fall behind. The global consulting group McKinsey estimates that an enormous 98% of large-scale construction projects incur cost overruns or delays. And the average large-scale construction project ends up falling 20 months — almost two years — behind schedule.
For the prevention of issues like these, it’s imperative to use the best, most efficient equipment on the market. When it comes to pouring concrete, concrete pumps offer substantial advantages in efficiency and ease of use.
THE SCIENCE BEHIND CONCRETE PUMPING
What is a concrete pump? A concrete pump is a tool used for transferring freshly mixed liquid concrete to the location on a construction site where it is needed. It works using a valve system and the basic principles of hydraulics.
When concrete is required, a mixing truck first mixes concrete within its rotating drum. Then the truck pours its liquid concrete into a hopper, which continues to churn the concrete so it will not solidify. From there, the concrete pump sucks the liquid concrete out of the hopper, through a valve system, and into the area where it needs to be laid down, sometimes with the use of auxiliary hoses.
A twin-cylinder hydraulic concrete pump’s internal workings typically consist of two parallel cylinders. The cylinders have drive pistons inside them that move them back and forth in opposite directions. As one cylinder moves forward, the other moves back. As one cylinder moves back, the other moves forward.
The first cylinder, also known as the material cylinder, pulls concrete out of the hopper. The second cylinder, the discharge cylinder, pushes the concrete out of the pump in the location where it is needed. The two pistons work in tandem, alternately pulling in and pushing out their volumes of liquid concrete. The hydraulic flow created by the continuous flow of concrete is what causes the two cylinders to alternate back and forth. This continuous flow is also important to keep the liquid concrete from solidifying.
DIFFERENT TYPES OF CONCRETE PUMPS
Concrete pumps come in a couple of basic varieties — line pumps and boom pumps.
1. LINE PUMPS
Line pumps pump liquid concrete in hoses at about ground level until the concrete reaches its destination. The hoses offer the flexibility to snake through alleys and around houses where the truck may not be able to park. Below are a few examples of types of line pumps:
Stationary pumps: A stationary pump, or trailer-mounted pump, is the most basic form of concrete pump. It consists of a pump mounted onto a small trailer. A separate truck is necessary to tow a stationary pump to job sites. A stationary pump also does not have a boom, so separate pipelines or placing hoses are necessary to carry the concrete from the pump to where it needs to go. A separate placing boom is also necessary to place the concrete precisely.
Truck-mounted static pump: Truck mounted static pumps are mounted onto truck beds, so employees can drive them directly to job sites. These types of concrete pump trucks don’t have placing booms, though, so they will require the use of separate placing hoses to get the concrete where it needs to go.
Truck mixer pump: This all-in-one model is a concrete mixer with a pump attached so it can pump directly from the mixer. This model is efficient in many applications, though it requires a job site setup that allows for driving a large mixing truck right up next to the place where the concrete must be poured.
2. BOOM PUMPS
A boom pump extends through the air to pump the concrete where it needs to go. It has a long, flexible, remote-controlled arm made up of articulated sections, and the arm extends into the air much like a crane. Boom pumps and can be used for hard-to-reach areas that a line pump cannot reach, such as the upper floors of a high-rise or apartment complex. They can also reach over houses and into yards for the construction of backyard swimming pools or garden features. When the boom is not in use, it folds up into neat segments on the back of the truck for transport.
Employees can drive this kind of pump directly to job sites, and the placing boom can put the concrete where it needs to go without requiring the use of extra hoses. These high-rise concrete boom pumps work quickly, and they can reach any area within reach of the boom. Their user-friendly features make boom pumps versatile and popular on construction sites.
The articulated sections of boom pumps come in a few different folding configurations:
Roll-and-fold: The sections of roll-and-fold pumps fold one under the next in a curling motion. They are ideal for wide-open spaces because they need plenty of room to unfold.
Z and ZZ: The sections of these pumps fold back and forth like an accordion. They are ideal for fitting through tight spaces and over and under obstructions, such as over a house and then under tree branches.
RZ: These pumps, also called multifold pumps, have sections are a combination of roll-and-fold and Z sections.
At DY Concrete Pumps, we specialize in boom pumps. All our boom pumps are fully drivable truck-mounted pumps with four, five or six articulated sections for superior horizontal and vertical reach. Each of our trucks has a chassis with three, four or five axles, depending on the size and weight of the boom pump.
A few of the many models we offer include the following:
57-meter 6-section RZ-fold boom pump (57X-6RZ): This is ourflagship modelof mobile concrete boom pump for medium and large construction sites. This pump is our longest and most productive. Its incredible vertical reach of 56.2 meters and horizontal reach of 52.2 meters make it ideal for tall buildings and extremely hard-to-reach areas, and its six articulated sections give it superior 360-degree mobility. Its remote control allows for precise, easy concrete placement.
43-meter 5-section RZ-fold boom pump (43X-5RZ): Thismedium-sized concrete boom pumpis ideal for both commercial and residential construction projects. Its vertical reach of 42.3 meters and horizontal reach of 38.3 meters allow for plenty of access to high places, while the more compact truck body makes it easy to park in residential spaces. Its articulated, remote-controlled arm makes it easy to navigate over or under tree branches and power lines.
33-meter 5-section ZZ-fold boom pump (33X-5ZZ): Thislightweight boom pumpis ideal for commercial and residential applications where mobility is a high priority. The five accordion-folding articulated sections of this pump allow it to reach into all kinds of hard-to-access areas, and its small size allows it to work in tight spaces, such as beneath bridges and in interior spaces with ceilings of 19 feet.
COMMON APPLICATIONS FOR CONCRETE PUMPS
Where are concrete pumps used? Concrete pumps are suitable for use in a wide variety of construction applications.
Slab building foundations: Buildings that don’t have basements have flat slabs of concrete as their foundations. It’s essential to have a solid foundation that won’t let in water and crack or sag. Concrete pumps are critical so the work goes quickly and smoothly and the concrete ends up where it should be. That way, no imperfections can occur in the foundation.
Building foundations with basements: For buildings with basements, the process of laying the foundation is more complicated. Concrete pumps like boom pumps are crucial so there are no time delays in which errors can occur or part of the concrete can harden before it’s ready. Using boom pumps for basement foundations helps ensure that the building project can be completed on time.
High-rise buildings: With high-rise buildings, a boom pump is often essential because of the elevation and reach it provides. Construction companies can use boom lifts to pump concrete to upper floors quickly, easily and safely and make sure the construction process remains on schedule.
Highway overpasses and tunnels: Highway overpasses must be made of durable, reinforced concrete to support the daily tonnage of traffic that passes over them. Roadway tunnels also must be strong enough not to collapse under the weight of the earth above them. Using a concrete pump makes sure the job gets done efficiently and effectively. Overpasses and tunnels also often involve working with some elevation, and the use of a concrete pump, especially a boom pump for its added lift, makes the job quicker and easier.
Bridges and dams: Bridges and dams must be large, strong and steady to support the weight of heavy vehicle traffic and intense water pressure. Boom pumps, in particular, offer the advantage of their lift and extension to ensure that concrete can pump quickly to the top of a tall bridge or dam..
Parking structures: Parking garages usually consist of several levels, and it’s hard to get concrete to the upper levels without a concrete pump. Using a concrete pump allows the construction of a tall parking structure to be completed quickly and with no wasted labor.
Sidewalks and driveways: In the construction of a new home, many homeowners focus most intently on the house itself. Still, the sidewalk and driveway are also essential elements. Some homeowners are tempted to pour the driveway and sidewalks themselves, but engaging a professional contracting company that can provide a concrete pump such as a boom pump is often the best bet for a smooth, stable and properly cured driveway and sidewalk.
In-ground swimming pools: An in-ground swimming pool has a concrete foundation, much the way a basement does. Concrete pumps, especially boom pumps, offer a particular advantage for the construction of backyard swimming pools. No one wants a heavy truck driving through the back yard, but a boom pump can easily reach over the house from the street and pour the concrete with minimal disruption to the yard.
Patios and garden shed foundations: As with backyard swimming pools, backyard patios and garden shed foundations are perfectly suited to concrete pumps like boom pumps. Boom pumps can reach into the backyard from the street and pour the concrete slabs for these features in no time.
Many of these applications call for the pouring of a flat concrete slab. But how long does it take to lay a concrete slab?
The pouring process itself happens quickly — potentially in less than an hour. Once it’s poured, though, the concrete needs to set a while. Typically, a slab can be walked on after 24 hours, but it will take longer for the concrete to become completely cured. A general rule of thumb in the construction industry is that it takes 28 days for concrete to reach its full strength, though some authorities believe the curing process is completed even sooner.
HOW HAVE CONCRETE PUMPS CHANGED THE CONSTRUCTION INDUSTRY?
The use of concrete dates from Roman times — both the Colosseum and the Pantheon contain significant amounts of concrete — but up until the early 20th century, with the invention of the concrete pump, pouring concrete was a labor-intensive affair.
Concrete pumps have been a dramatic advantage for the construction industry. Imagine a construction worker in the early 1900s pushing a wheelbarrow full of concrete, making trip after trip after laborious, sweaty trip, until he had finally poured the modest amount of concrete necessary for the project. This method is inefficient, time-consuming and labor-intensive. The concrete pump provides a much easier and faster way of moving concrete.
Concrete pumping trucks have been particularly transformative in high-rise construction. Before the invention of the concrete pump, cranes had to lift heavy buckets of concrete into the air toward higher floors. A bucket holds only a small amount of concrete, so this process was inefficient. Modern concrete pumps can pump much faster than cranes can lift buckets, and they allow for a continuous flow of concrete. They also enable the concrete to be poured directly via a placing boom rather than being transferred sloppily in a bucket.
Concrete pumps offer many other benefits as well. Because they work continuously, they can pump substantial volumes of concrete at a time. Because the concrete is always flowing, employees are constantly busy, never standing around and waiting for concrete to arrive by other methods. A concrete pump can be set up very quickly, and it requires only a small number of employees to operate it. All these features make concrete pumps essential user-friendly, efficient and time-saving features on any construction site today.
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What is a Concrete Pump?
What is a Concrete Pump?
Background to Concrete Pumps
A concrete pump is a tool for conveying liquid concrete.
Over a period of more than half a century, concrete pumps have slowly taken over from other methods of transferring liquid concrete. A number of different designs of concrete pump were developed in the first half of the 20th century but it was Friedrich Wilhelm Schwing's company Schwing GmbH which invented the twin cylinder hydraulic concrete pump in 1957. The principle of this design was adopted by almost all other manufacturers and is still the worldwide standard design.
The pump works by one piston drawing liquid concrete into a cylinder from a hopper while the other one simultaneously pushes its concrete out into the discharge pipes. A valve which determines which cylinder is open to the concrete hopper and which one is open to the discharge pipes switches over each time the pistons reach the end point (see rock valve below and animation left - click to enlarge) and the process continues with the first cylinder now discharging and the second drawing fresh concrete from the hopper.
The Concrete Pump was particularly important in revolutionising the construction of large high rise buildings. Previously cranes had been employed to lift large buckets (or skips) full of concrete up to where it was needed. A crane could lift one bucket at a time, normally holding around 2 cubic yards of concrete.
There are many advantages in pumping concrete over this bucket and crane system. As well as being able to pump concrete much faster than buckets could lift it, it also means a constant supply of concrete to the top and the placing hoses can be positioned wherever they need to be so the liquid concrete can pour straight out of the hose where it's needed rather than having to distribute a two cubic yard mound of concrete over the desired area.
Advantages of concrete pumping over lifting it up in skips via a crane:
Much larger volume of concrete placed per hour. A crane would be doing well lift 12m³ per hour. A Schwing Static Pump can pump over 50m³ per hour to the top of today's tallest high rise buildings.
Constant flow. Today's Schwing Concrete Pumps can pump concrete as quickly as a truck mixer can discharge into them. Even as fast as two truck mixers can discharge in many situations.
Fewer wasted man hours. The people placing the concrete need to wait for the next batch while the skip is in motion or being refilled at the bottom. The people at the bottom are just waiting for the skip to come back down while it is in motion or discharging at the top. The continuous flow from a concrete pump means less waiting around.
The crane can perform other tasks. Instead of lifting buckets of concrete up and down, the crane can be employed to deliver steelwork, scaffolding, formwork and all the other necessary building material to where it needs to be.
Concrete placed straight where you want it. The placing hose can be moved around so that concrete can be placed wherever it is needed. A Separate Placing Boom can also be employed to position the end hose exactly where it is needed within a large area. Mobile concrete pumps come with their own dedicated placing boom.
Lower Labour Costs. Because the concrete can be placed exactly where it is needed, only a minimum number of people are required to distribute the concrete - unlike when a skip dumps a load and people are needed to then move the concrete to where it is needed.
Quicker setup times. A mobile pump can arrive on site, extend its outriggers and boom and be pumping concrete many floors up within an hour. It can even do two or even three such jobs in a day.
The Rock Valve
As demand grew for concrete to be pumped further and higher, the flat gate valve in use at the time could no longer cope with the pressures required and in 1982, Schwing patented the revolutionary "Rock Valve". This was able to work with far higher pressures, allowing the heights and distances for concrete pumping to be greatly increased. The high pressure in the Rock Valve system helps seal the valve rather than working against it.
The wide mouth of the Rock Valve also helps keep the system stable and is extremely low wearing due to the low friction design. The abrasive concrete is only scraping against one side of the valve at any one time, nearly halving the amount of wear compared to other designs.
Placing the concrete
Pumping the concrete is one aspect of the overall task. Another is controlling where the concrete is placed. Whilst this can be done by manually positioning the end hose, a remote-controlled articulated placing boom is often used to position the placing hose exactly where the concrete is needed. The robotic arm is designed to unfold is a small area and be able to reach every spot within the length of the boom. Even if there are difficult barriers and constraints in the area. The pipe runs the length of the boom and a placing hose on the end can be positioned to place the concrete precisely where it is needed, quickly and easily.
Types of Concrete Pumps
Other than capacity, the main difference between the various types of concrete pumps is determined by the additional equipment that comes as part of the pump. A concrete pump in its simplest form is best represented by a Stationary Concrete Pump. Additions to this, resulting in other types of concrete pump are:
Transport - a dedicated vehicle to transport and position the pump,
A Boom - a dedicated placing boom attached to the pump,
and even a Truck Mixer - to store and supply the concrete.
A Mobile Concrete Pump, also known as a Truck Mounted Mobile incorporates both a concrete pump and a placing boom mounted onto a truck chassis. Mobiles come with booms ranging from less than 20 metres to ones which can reach heights of over 60 metres. The advantage of a mobile pump is that it can turn up at a job and be pumping concrete very quickly to anywhere within the range of the boom. This makes mobile boom pumps very popular on the widest range of construction projects, being able to pump at very high volumes quickly to wherever concrete is needed with minimum labour requirements.
A Static Concrete Pump, also referred to as a Stationary, Line Pump or Trailer Mounted Concrete Pump is mounted on a trailer and requires a separate pipeline to be attached reaching to wherever the concrete needs to be placed. The pipeline is a series of steel or rubber pipes, known also as concrete placing hoses, linked together and manually attached to the outlet of the pump. The other end of the pipe could either be attached to a Separate Placing Boom, allowing the concrete to be placed with precision quickly over a wide area or it might just finish with a rubber placing hose for manual placement. A Static Pump needs to be towed or separately transported to jobs.
The advantage of a static pump is that the pipeline can be long so that the actual pump can be very far away from where the concrete is being placed; maybe hundreds of metres below or even kilometres away. This makes static pumps essential for tunnelling work and high rise constructions. Static Concrete pumps come in a far greater range of capacity than those used on Mobile pumps. From smaller pumps ideal for residential and low rise work right up to the SP8800 which can reach pressures up to 243 bar and pump over 100m³ per hour. It is a middle of the range SP4000 which holds the World Record for pumping concrete to the highest vertical distance. (The job also included a horizontal component of over 1km.) A pumping distance has yet to be found which cannot be done by a Schwing pump.
Truck Mounted Static Pump
A static pump can also be mounted onto a truck chassis but without a boom, resulting in a Schwing Truck Mounted Static Concrete Pump. These are perfect for the many quick jobs where a boom might not reach. It might be a slab for an extension at the back of a home or garden where running a pipeline through or round the building is the only option. A normal static pump would need to be towed or delivered on a Hiab truck but with the Truck Mounted Static Pump, the operator can drive it straight to site. Schwing Truck Mounted Static Pumps also come with storage for up to 100 meters of pipeline and other accessories so everything needed is in one place allowing the operator to pack up and head straight to the next job as soon as a work is completed.
Truck Mixer Concrete Pump
Another aspect of concrete placement is the supply of concrete. Both Mobile and Static Pumps have a large hopper to receive concrete from a truck mixer. However Schwing Stetter offers a mobile product which also carries a supply of concrete with it. The Fahrmischer Beton Pumpen (truck mixer concrete pump) combines not only a pump and boom but also the concrete storage and transport in the form of a mixer truck, all in one package.
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Quality Requirements of Pumped Concrete
Quality Requirements of Pumped Concrete
Many factors like length, number of bends in the line, type of pipe, size of a line, height to which the concrete is being pumped, and the concrete mixture influence the working capacity of a concrete pump.
1) Pump Lines
Pipelines used in concrete pumps are generally a combination of rigid pipe and heavy-duty flexible pipe. The acceptable rigid pipe can be made of steel or plastic and is available in sizes from 3 to 8 inches in diameter.
The aluminum alloy pipe should not be used as a pump line. The flexible hose is made of rubber, spiral wound flexible metal, and plastics. If possible, the pipeline should be of one size and laid out to contain a minimum number of bends.
2) Mixture Proportions
Proportions of concrete ingredients of pumpable mixtures are essentially the same as those to be placed by other methods. Concretes which are pumped must be cohesive.
Harsh mixtures do not pump well. The pressure exerted by the pump can force the mortar away from the coarse aggregate causing a blockage in the line if the mixture is not proportioned properly.
The content of cement will generally be slightly higher for pumped mixes than those of mixtures placed by conventional methods.
3) Coarse Aggregate
The nominal maximum size of the coarse aggregate is restricted to one-third of the inside diameter of the pump for crushed aggregates or 40 percent of the smallest inside diameter of the pump for well-rounded aggregates.
Oversize particles should be eliminated. Excessive mortar content will be necessary to effectively pump a concrete containing crushed aggregates than for concrete containing rounded aggregates.
4) Fine Aggregate
The properties of fine aggregates as an ingredient in concrete are more critical in proportioning pumpable mixtures than are the properties of the coarse aggregates.
Combined with the cement and water, the fine aggregates compose the mortar which transfers the coarse aggregates in suspension through the pump line.
Both types of aggregate manufactured fine aggregates and natural sands can be used in pumped mixtures.
The necessity of water for optimum slump and to maintain control of that slump throughout a pumping placement are both extremely important factors.
Concretes having slumps less than 2 inches when delivered to the pump are difficult to pump. Concretes having slumps over 6 inches can segregate causing a blockage in the pump line and may require a pumping aid to increase the cohesiveness of the concrete mix.
Materials which enhance workability, such as water-reducing agent, high-range water-reducer, and air-entraining admixtures, as well as pozzolanas, usually improve pumpability.
It is usual to experience a decrease in air content during pumping. The specified air contents essential for the durability of concrete should be obtained at the point of placement on the site.
Therefore, it may be necessary to entrain a higher air content into the concrete mixture before pumping.
Proper arrangement of the whole pumping operation including pump location, line layout, placing sequence, and concrete supply will result in savings of time and expense.
The pump should be feasible as near the placement area as possible. Concrete conveying systems should have easy approaches to the pump.
Pipelines from the pump to the placement area should be made up of rigid pipe and contain a minimum number of bends.
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