How To Install Concrete Pump Pipelines?

Concrete Pump Machine Layout

How To Install Concrete Pump Pipelines?  The layout of the concrete pump machine is crucial, and attention should be given to the following aspects:

• Once the concrete pump is delivered to the construction site, it should be positioned away from slopes, embankments, trenches, etc. Consider easy access when loading and unloading the transport truck and try to minimize the length of the pump line.
• The concrete pump must be placed on a solid, level surface, preferably with a flat concrete foundation and a simple shed for protection. A stable foundation is essential for safe and efficient operation.
• After positioning the pump, adjust its height using a jack so that the pump’s wheels are off the ground. Secure the pump’s legs with outrigger pins to ensure stability during operation. Ensure that the hopper door opens and closes smoothly for material clearance. If the pump will not be moved for an extended period, the tires can be removed for added safety.
• Around the concrete pump’s work area, ensure an adequate water source and well-functioning drainage facilities. Proper lighting should be installed to maintain visibility during all hours of operation.
• Maintain a clear working space of at least 1 meter around the pump for the safety and convenience of operators.
• When transitioning from pumping at low pressure to high pressure, reposition and secure the pump to ensure stable and reliable operation. These precautions are vital to maintain the integrity and efficiency of the concrete pump during your construction project.”

Concrete Pump Pipe Layout

The layout of concrete pump pipes is crucial, as it directly impacts the efficiency of concrete pumping. Consider the following important principles:

• Concrete piping should not be subjected to external tension.
• Piping layout should follow the principles of the shortest distance and the least number of bends.
• Conveying pipelines should be placed in locations easily accessible for personnel to clean and replace.
• Each pipeline connection must be secure and stable. Bend pipes should have firm fixed points to prevent pipe shaking and loosening during pumping.
• Pipe clamps should not make direct contact with the ground or supporting objects. There should be a gap for easy dismantling and installation. Ensure that each pipe clamp is tightened to prevent leaks and air ingress.
• Horizontal pipes should not hang in the air and must be securely fixed. For prolonged operations, the pipes should be supported by wooden pads.
• At the outlet of the cone pipe, bend pipes should not be connected directly. At least 5 meters of straight pipe should be connected before attaching the bend pipe.
• For pipes located 3 to 5 meters from the machine, they should be fixed with 1 to 2 cubic meters of concrete blocks. These blocks help absorb the counterforce and reduce pipe vibrations.
• When laying delivery pipes, place concrete farthest from the machine first to avoid pipe connections during operation.
• In the summer, protect pipes exposed to direct sunlight from blockages by covering them with wet grass bags or similar materials. In winter, when temperatures drop below -5°C, insulate the pipes with grass bags to maintain concrete temperature.
• Fix the conveying pipe connected to the cone pipe at the machine’s outlet to facilitate pipe dismantling for cleaning after stopping operations.
• Pipes located close to the machine or in areas where personnel need to step should be screened with protective covers to prevent pipe cracking and clamp loosening.

Vertical Pipeline Layout

For vertical pipeline layouts, consider the following guidelines:

• Vertical pipes can be laid along elevator shafts, scaffolding, or through prefab floor holes to facilitate pipe dismantling.
• Use new conveying lines when installing vertical pipelines. For greater heights, use thicker pipes at the bottom. The underside pipes should be easy to dismantle. Bend pipes should not be used for vertical pipe support; instead, each pipe should be supported by 1 to 2 bolsters. Secure straight and bend pipes to walls, scaffolding, towers, or elevator shafts to transfer the concrete’s gravity load to the building structure.
• As the vertical pipeline’s height increases, a certain length of horizontal pipeline should be laid between the machine and the vertical pipeline to resist concrete flowing backward and impacting the S-valve. The length of the horizontal pipeline should be at least 15% of the vertical pipeline’s length, and a cut-off valve should be installed at the machine’s outlet for high-level concrete delivery.
• For long-distance pumping with a large concrete output, you can install two parallel pipelines. If one line becomes blocked, the other can continue working.

Vertical Downward Pipeline Layout

When pumping concrete downwards, especially when the drop in height exceeds 6 meters, follow the layout as shown in the figure below to prevent concrete segregation. When pumping mortar, insert sponge balls into the pipeline at various heights every 20 to 30 meters to ensure continuous pumping.

Please note: The table for pipe conversion is an empirical value obtained through testing under specific concrete conditions and is not a theoretical value. It should be used as a reference for piping layout and may vary depending on the concrete being pumped.

By adhering to these concrete pump and pipe layout principles, you can ensure safe and efficient concrete pumping operations on your construction site.