Concrete pump pipeline is used to transport the concrete in the concrete pump system before start the pumping work, concrete pump pipeline should lay well firstly.
Concrete Pump Pipeline layout pattern at the pump exit
There are three pipeline layout patterns at the pump exit which are determined by the on-site construction conditions (see Figure 1)
- Direct connection. After connecting the pump exit with the taper pipe, the pipelines shall be laid straight ahead.
- U-shape connection. After connecting the pump exit with the taper pipe, a 3m straight pipe should be installed and connected with two pieces of 90° bend pipes to make them to a 180° horizontal bend pipe.
- L-shape connection. After connecting the pump exit with the taper pipe, a 3m straight pipe should be installed and connected with a 90° horizontal bend pipe.
Different connection methods have different advantages and disadvantages. Direct connection has small pumping resistance; however, when the pumping height is bigger, the concrete is likely to flow back; therefore, the direct connection is suitable for horizontal concrete delivery or below horizontal concrete delivery. U-shape connection has higher pumping resistance; however, when the pumping height is bigger, the concrete is not likely to flow back; therefore, U-shape connection is suitable for high-altitude concrete pumping. The pumping resistance of L-shape connection falls in between the above two levels; however, it has large transverse reacting force; therefore, the exit cone shall be fixed tightly.
Basic principles of concrete pump pipeline layout
⑴ Do not apply any external tensile force for the concrete delivery pipeline.
⑵ The pipeline layout shall follow the principle of “the shortest distance and the smallest bend”.
⑶ The delivery pipeline shall be easily accessible for cleaning and delivery pipeline replacement purposes.
⑷ Each pipeline must be connected tightly and stably. Set additional fixed point at the bend joint to avoid pipeline shaking or getting loose in the process of pumping.
⑸ Each pipe clamp shall not connect with ground or support. There shall be a certain space between them for dismounting. Meanwhile, each pipe clamp must be tightened properly to guarantee that each joint is sealed well and is free from fluid leakage or air leakage.
⑹ The horizontal pipeline shall not be off the ground and shall be supported solidly. When the delivery pipeline has to work for a long time, the pipeline must be supported by wood backing (Figure 2).
⑺ Do not install bend pipe at the exit cone of pump directly. The operating personnel shall connect a straight pipe which is more than 5 meters in length with the exit cone first, and then connect the straight pipe with a bend pipe.
⑻ Pour a concrete block on the delivery pipeline which is 3 to 5 meters away from the pump for fixing the delivery pipeline, absorbing the reacting force caused by concrete flow in the pumping process, keeping the pump stable and reducing the delivery pipeline vibration. The volume of the concrete block is 1 to 2m3 (Figure 3).
⑼ The pipeline shall be poured from far to near and shall be back away gradually. Do not install any pipes in the pumping process to prevent any influences on operation
⑽ When the pipeline is exposed to intense light in summer, the pipeline is likely to be blocked because of concrete dehydration due to overheat; therefore, the pipeline shall be covered by wet straw bags or the other protection products. When the temperature is -5℃ in winter, the delivery pipeline shall be covered by straw bags for moisturizing, to guarantee the proper concrete molding moisture.
⑾ The delivery pipe connecting with the exit cone of pump directly must be fixed properly, so that it will be easy to dismount the pipeline for cleaning every time after the pumping operation stops.
⑿ The delivery pipeline which is near to the pump or is easily accessible by the personnel shall be covered by necessary shields to avoid human injury due to pipe break or pipe clamp looseness.
Vertically upward concrete pump pipeline layout (Figure 4)
⑴ The vertically upward delivery pipeline can be laid upward along the elevator shaft or scaffold. It can also pass through the roof hole for pipeline dismounting purpose;
⑵The vertically upward delivery pipeline must be new pipes; when the height is larger, the bottom pipe shall be thick-walled pipe and the down-most bend pipe shall be easily-dismounted thick-walled pipe. Do not use bend pipe to support the vertical pipeline. Set one to two supporting points on each pipe for support purpose. Use clamps to fix the straight pipe and bend pipe on wall, scaffold, tower crane body or in elevator shaft to transfer the gravity of pipeline and delivered concrete to the building through the supporting points (Figure 4).
⑶ With the increasing height of vertical pipeline, the delivered concrete is likely to flow back and to cause impact on S-pipe. In order to weaken such impact force, a certain length of horizontal pipeline shall be laid between the pump and the vertical pipeline to assure that there is sufficient resistance to stop concrete from flowing back. Usually the length of the horizontal pipeline shall not be less than 15% of the length of the vertical pipeline. In the process of high-level pumping, a pipeline stop valve shall be mounted in the horizontal pipeline of the pump.
Vertically downward concrete pump pipeline layout (See Figure 5)
In the process of delivering concrete vertically downward, the pipeline shall be laid according to Figure 5 to avoid concrete disintegration when the falling head is greater than 6m. In addition, in the process of pumping mortar, the operating personnel shall put sponge balls in the different-height pipeline at the interval of 20 to 30 meters to guarantee the successful pumping.
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