Truck Mtd Conc Pump - Final

8/10/2019 Truck Mtd Conc Pump - Final

http://slidepdf.com/reader/full/truck-mtd-conc-pump-final 1/50

On the job training on

“Truck Mounted Concrete Pumps”





Truck mounted concretepump / placer

•The two cylinder reciprocating pumps, sucks concrete from the hopper

and pushes to the delivery line. Both the cylinders do this function

alternately. The pumping operation is achieved mainly with two of gate

valves.

Rock valve

Flat gate valve

Rock valve

In this, a conduit is pivoted inside the hopper in such away that the

cylinder is always connected with the feeding hopper and the

pushing cylinder with the delivery line.



Flat gate valve

The concrete contained in the changing hopper is sucked into the

pumping cylinders and then pumped into the delivery pipe line by

pumping pistons. The two pumping pistons operate in opposite

directions i.e. While the returning piston sucks the concrete out of the

hopper and thus fills the cylinder with concrete , the other piston

moving forward pushes the concrete sucked in during the precedingstroke into the pipe line . The gate valve plates are arranged in such a

manner that the suction stroke, the cylinder is connected to the

hopper and separated from the delivery line and vice versa.

Contd.

Truck mounted concrete

pump / placer





Checks and maintenancebefore concreting

Check oil level in hydraulic tank concrete pump. oil may fluctuate only

within the range of vision.

Check oil level in hydraulic tank placing boom with the completely

unfolded boom, extended cylinder, the oil level must still be visible in

the level glass.

Check oil tightness in hydraulic system(visual checks,tightens leaky

connections).

Check water box quantity.(water box should be full to the top edge of



Checks and maintenance

before concreting

Check flushing agent for gate valve rods.

Check for proper changeover of cylinder at low speed.Gate valves

must reach limit stops when engaging concrete pump.If necessary ,

slowly close throttle valve on control block until gate valve hits

gently against limit switch.If impact of gate valve is too hard, slightly

open both throttle valve.

Check water tank level.

Check function of water pump.

Check function of placing boom.

Contd.



OPERATING PROCEDURES

Under all circumstance keep a safe distance from obstacles such as

masts, scaffolds, buildings, etc.

The placing boom may be operated only up to max wind force 8

(wind velocity = 77 km/hr).

The placing boom must never be used as a crane for lifting loads.

Un-authorised persons in the working areas of the concreting pump

and the placing boom is prohibited.

Contd.




The vehicle must not travel with boom unfolded.

The rubber end hose at the placing boom must not exceed the

length as specified. It should not be linked during pumping

operations. The safety rope for the end hose must be available and

fixed.

Connections of delivery pipelines must not be opened under

working pressure. Before opening the pipelines it must be relieved

from stress by sucking back the concrete in reverse. After

assembling the pipeline secure the pipe couplings.

Never bend the end hose at the sharp angle

Contd.




When blowing out the placing boom pipeline, the end hose must

be removed and the trap basket attached. It must also be ensured

that no persons are standing at the pipeline end in blowing out

direction.

Do not allow the hopper to be pumped completely empty. This

may cause trouble due to air locks (concrete analyzing due to

compressed air in the cylinder ) and running the pistons dry

Contd.




If the flushing agent is excessively contaminated, it should be changed.

Where it is absolutely necessary to change the sealing set for the gate

valve rods after Concreting operation. If stones have jammed the

agitating arms in the agitator, engage the agitator reverse for a short

time.

Check tightness in the hydraulic system(visual control,tighten leaky

unions).

Contd.




A well cleaned delivery pipeline helps prevent blockages.

If blockages occur (concrete pump stops working, safety pressure

has been reached), switch over to “trouble “ (reverse pumping ) for a

few strokes by means of switching lever. If blockages has not been

cured after switching back the concrete pump to “operation”, the

concrete pump has to switched off.Then establish where the blockage

is normally the blockage occur in the area of the reduction pipes or the

end hose.

Contd.



SAFE OPERATING PROCEDURES

During operation of the concrete pump its operator is responsible for

the complete working of equipment. When leaving the concrete pump

unattended, he must secure it against unauthorized use.

Rectification of any failure, repairs and maintenance work should only

be made with drive motor disconnected.

On slopping sites the wheels be secured with blocks, release the

brake and let the machine run against the blocks, then apply the brake.

Finally support the machine.

Keep adequate distance from foundation trenches. The support

pressure may cause breaking off the slope.



SAFE OPERATING PROCEDURES

Jack the machine in such a manner that it stands in a horizontal

position, having achieved this, close and lock the valves of the jacking

cylinders, otherwise oil by-pass will occur and the machine could sink to

one side.

To prevent air cavitation the hopper must be filled as a minimum

with concrete approximately up to the agitator shaft. Cavitation may

cause the concrete to blow out of the hopper. Never place hand into the

concrete gate valve or the agitator hopper while the machine is running.

If the concreting with pump was doing with remote control, and after

the machine has been switched-off, always place the lever “concrete

pump-forward/reverse” initially into neutral position, otherwise the

concrete pump will become re-engaged.

Contd.







(ROCK VALVE TYPE)





CLEANING AFTER CONCRETING

After concreting, the pipeline of the placing boom and concrete pump

must be cleaned carefully.

There are three methods of cleaning the pipe Line

1. Sucking out the pipeline :

Before sucking out the pipeline it is advisable

To produce and pump a quantity of high slump Concrete to fill the

pipeline.




The hopper should slowly be pumped empty as far as possible.

Position placing boom so that the last boom section with its end

hose hanging vertically towards the ground and within easy

reach. Push into the end hose a soft rubber sponge ball. Engage

concrete pump to "trouble" (reversing the pumping). The

concrete in the pipeline together with the ball will be sucked back

into the hopper.

Disconnect the siamese and bend, swing them sideways and

flush. Empty the hopper and clean.

Contd.




2. Pumping out the pipeline

The siamese and pipe bend have to be disconnected and both swing

sideways. Remove the concrete from the connecting pipe until a soaked

paper plug followed by a soft rubber sponge ball can be pushed in into

the reduction pipe. Connect cleaning head and connect the water pump

hose. Engage water pump. When discharge of paper and rubber ball

occurs at the end of the pipeline, turn-off the water pump flush the

siamese, pipe bend and hopper

Contd.




Blowing out the pipeline : This method is similar to pumping out the pipeline method; but instead

of water line air line to be connected to the cleaning head, and connect a

trap basket at the end of pipeline.

3. Flushing of pipeline :

By flushing the pipeline remaining of concrete are removed from the pipe

walls.

For this purpose push the rubber ball about 1 m into the reduction pipe,

sprinkle water into the reduction pipe and close the pipe with another

rubber ball, so that there are a few litres of water between these two

rubber balls. Attach cleaning head. Now push the two balls with the

water cushion through the pipeline with compressed air.

Contd.



CONCRETE TECHNOLOGY PREREQUISITES

The following defects give rise to non-pump ability of a freshly

mixed concrete. Faulty concrete composition.

Insufficient content of fines per cum of fresh concrete.

Consistency too stiff.

Insufficient homogeneous mixing quality of fresh concrete.

Segregation of fresh concrete owing to inexpert transportation to

construction site.

Bleeding of fresh concrete.

Unsuitable granulometry.

Wrongly selected maximum size of aggregate in relation to nominal

diameter of the delivery pipe line.



Schwing BPL580-18/KVM28-24concrete placing pump and boom

The concrete pump

Mounting

It is possible on various truck chassis with a minimum admissible total

weight of 14t by means of fitted sub-frame

Drive unit

Truck engine drives via flexibility suspended intermediate gearbox -

changeable to pumping or travelling operations - the constant axialpiston pumps for concrete-pump,placing- boom & auxiliary

groups.Pumps work in a reliable open hydraulic circuit,engine speed is

controlled by a rqv speed governor




Control system :- Full hydraulic control- Compact control block-

automatic control of constant stroke

Pumping cylinders :- 2 nos. Hardened by Special process and hard

rubber rams with Metal core

Gate valve :- Single rod gate valve with automatic adjustment

and quickly replaceable shells

Charging hopper :- 460 ltr capacity Hopper with rubber & grill

reversible Agitator driven by hydraulic motor, with Robust bearing and

sealing of agitator Shaft




Optional equipment

A) air compressor

B) oil cooler

C) lateral outlet

Operating data •Theoritical output 52 cum / hr (max)

•Concrete pressure 55 bar (max)

•Number of strokes 28 per min (max)

•Pumping cylinder 180 x 1200 mm

•Stroke volume 61 ltrs (2 cylinders)

•Hopper capacity 460 ltrs

•Drive power 130 hp (min)

•Weight 3280 kg




The placing boom

Boom construction Boom made of high quality, fine grained steel in

box. Type construction, providing low weight and high safety in

vertical plane 3 times foldable, mounted on a slew able base column

with robust slewing drive. Folding angle of flyer of 245 deg. Resp.220

deg.

Jacking system 4 hydraulically telescopable support feet, front-

feet at laterally slewable outriggers jacking exclusively effected via




Delivery pipeline :- DN 125mm made of highly wear resistant

material uniform pipe lengths & bends thus equal on all boom sections

All articulated joints, also on boom end , consists of pipe bend.

Standard 90 deg bends are thick walled and wear resistant.

Drive & control :- Drive is by hydraulic pump actuation of

placing by positive hydraulics valves operated manually or via a remote

control.

Pumping material :- Pumpable concrete within any consistency

range down to a water / cement ratio of 0.4 max. Aggregate size upto

63mm depending on delivery pipeline diameter




Operating data

Pipeline dia 12 DN

Vertical reach 27.7 mtr

Horizontal reach 24 mtr

from

Slew axis center

Height of folding points (in mtr) 3.7 - 12.25 -

20.3

Articulated points three

Hoisting angle 104 deg




The concrete pump

•Mounting

Mounting is possible on various truck chassis with a minimum

admissible total weight of 22t by means of a fitted sub-frame

•Drive unit

Truck engine drives via auxiliary drive or a flexible suspended

intermediate gear box - changeable to pumping or travelling operations

- the constant axial piston pumps for concrete -pump.Placing-boom &

auxiliary groups. Pumps work in a reliable open hydraulic circuit.

Engine speed is controlled by a governor.




Control system :- Full hydraulic control- compact control block

automatic maintenance of constant stroke

Pumping cylinders :- Two nos. Hardened by special process and

hard rubber rams with metal core

Gate valve :- Single rod gate valve with automatic

adjustment and quickly replaceable shells

Charging hopper :- 500 ltr capacity hopper with rubber & grill

reversible agitator driven by separate hydraulic Pump and motor, with

robust bearing and sealing agitator shaft.




Optional equipment a) air compressor b) oil cooler

b) lateral outlet d) vibrator

Operating data

Theoritical output 60 cum / hr(max)

Concrete pressure 70 bar (max)

Number of strokes 31 per min

(max)

Pumping cylinder 180 x 1400mm

Stroke volume 72 ltrs (2

cylinders)

Hopper capacity 500 ltrs

Drive power 130 hp (min)






Delivery pipeline

Dn125mm dia. Made of highly wear resistant Material uniform pipe lengths

& bends. Thus Equal on all boom sections. All articulated Joints, also on

boom ed,consist of pipe Bends.Standard 90deg.Bends are thick walled And

wear resistant

Drive & control

Drive is by hydraulic pump actuation of Placing boom by positive hydraulic

valves Operated manually or via a remote control

Pumping material

Pumpable concrete within any consistency Range down to a water / cement

ratio of 0.4 Max.Aggregate size upto 63mm depending on Delivery pipeline

diameter.




Operating data

Pipeline dia 125 DN

Vertical reach 27.7 mtr

Horizontal reach 24mtr from slew

Axis center

Height of folding 0.7 - 12.25 - 20.3

Points (in mtr)

Articulated points ThreeHoisting angle 104 degree

Slewing range 360 deg

Weight 5900 kg




• Capacity of oil tank : Approx.480

L

• Capacity of water tank : Approx.500

L

• Capacity of charching hopper : Approx.500

L



The technical details of other models ofSchewing make boom placers

BPL units 801 (r) 900 hdr 1200hdr

Max Hyd. pressure bar 280 280 300

(concrete pump)

Max.Hydraulic pressure bar 100(200) 200 200

(Agitator)

Pumping cylinder,diamm 200 * 1400 200 * 1600 230 * 2000 *stroke

Required power kw 74 74 74

Max Theoritical - 31(33) 30 17 * 26 16 * No of strokes

Per minute

Max concrete pr. Bar 57 (61) 60 08 * 57 96 *

* = piston side admission.



Putzmeister BPF 08/M24Concrete placing pump & boom

Concrete pump

Design :- All drives and concrete conveying parts are mounted on

an auxiliary chassis. This frame is prepared for mounting on truck chassis

having gross vehicle weight of 15tons or more & drive power of 110hp &

mounting of concrete placing boom

Drive :- The pump is driven via a PTO of truck engine.

Alternatively a splitter gear box can be fitted in between the propeller

shafts where all necessary hydraulic pumps are flanged on.




Concrete pump

Consist of a pump chamber and hydraulically powered rotor with 2

rollers which turn around a center shaft, while pumping a special hose

embedded pumping chamber is squeezed by the action of 2 rollers,

thereby pushing forward the concrete mix inside the hose into the

conveying line vacuum within pump chamber ensures that pumping

hose regains its former cross section immediately behind rollers &

enables the concrete to be sucked in from the feeding hopper at a

high volumetric efficiency




Placing boom

Design :- M24 boom is constructed in modern 4-arm, zr

fold design trapezoifdal boom pedestal with diagonal support (trd)

provides secure support.

Construction :- Stable steel boom pedestal takes entire support force.

The boom arms of high quality fine grained steel in box type design. All

the arms are positively & hydraulically operated. The pivot joints with

optimum angle range & slewing gar provide excellent flexibility and slip

characteristics.The extendable diagonal legs at front in conjunction with

rear pump support & axle locking provide necessary stability, support

legs are all hydraulically operated




Concrete pump

Concrete mix

Pumpable concrete of all consistencies to 1”slump (k1)with 32 mm

aggregate maximum

Others

A) Water pump 400lc/w 30 bar with 10mtr ho (standard) 100 bar

pump ( optional)

B) Air compressor 10 bar pressure , hydraulically operated




Placing boom

Delivery line

The boom is equipped with a DN 125 ih delivery line. Pipe sections are

connected by clamp couplings. End hose is suitable for operating pressureof upto 85bar

Boom control module

All boom movements are made by hydraulics and can be carried out

simultaneously .Safety valves mounted directly on arm cylinders serve as

protective device in case of hose rupture and over loading. Hydraulic

control block (mbc) is mounted on boom pedestal and fitted with large

hand levers for emergency operation.








Placing boom

Horizontalreach from middle of 19.6 mtr

Slewing unit

Maximum vertical reach 23.2 mtr

Maximum depth of reac 14.6mt

End hose length 4.0mtr

Delivery line diameter 125mm

Slewing range 360 0

Slewing speed 0.61 rpmMaximum support leg force 113 kn

Working pressure (hydraulic) 300 bar

Remote control 24 volts




Arm length Angle

range

Arm 1 6.370 mtr a 110 deg

Arm 2 4.380 mtr b 180 deg

Arm 3 4.452 mtr c 245 deg



CONCRETE BOOM PLACER



ITEM ACTIVITY

D A I L Y

W E E K L Y

M O N T H L Y

5 0 0 H R

S .

1 0 0 0 H

R S .

2 0 0 0 H

R S .

8Change oil in transfer case resp. in switchable

divider gearbox. o

9Clean hydraulic oil cooler , more frequently in

case of excessive ratio of dust. o

10Drain condensation water from the hydraulic oil

tank. o

11 Grease propler shaft of the hydraulic pump drive o

12Grease all placing boom articulations and the

lubricating ponts of the outriggers o

13Grease the step and collar bearings of the boom

column as well as the sliders of the slewing gear o

14Lubricate all levers , articulations, etc by means

of oil can with engine oil o

15Check setting of pressure limit valves respective

hydraulic oil pressures. o

Maintenance schedule Contd




ITEM ACTIVITY

D A I L Y

W E

E K L Y

M O

N T H L Y

5 0 0

H R S .

1 0 0

0 H R S .

2 0 0

0 H R S .

16

Check the fastening screws resp. anchor bolts of

the auxillary frame. The placing boom , the

differentioal and the pumping cylinders for tight fito

17 Check fastening of pumping pistons. o

18 Visual check for exterior damages o

19 Check oil level in agitator gear. o

20 Change oil in agitator gear o

21Check the functioning of the control checking ,

safety and emergency devices. o

22 Grease all lubricating points of the agitator. o

23Grease the lubricating points of the Rock Valve

and the slewing cylinder o

24Check the fastening screws of the Rock Valve

cover for tight fit. o

25 Check the clamping screws of the pivoting body ofthe rock valve for tight fit o


i



ITEM ACTIVITY

D A I L Y

W E E K L

Y

M O N T H

L Y

5 0 0 H R

S .

1 0 0 0 H R S .

2 0 0 0 H R S .

26Check the adjusting nut of the Rock Valve pivot

shaft for play in axial direction o

27 Check the cutting ring of the Rock Valve o

28 Check the setting of the throttle valves. o

29Check the oil level and the contamination in the

flushing containers , change oil if necessary. o

For concrete pumps with flat gate valves the items 23,24,25,26,and 27 are not applicable

The Rock valve pumps the items 28 and 29 are not applicable.

REMARKS

ContdMaintenance schedule

Truck Mtd Conc Pump - Final

Documents