truck mtd conc pump - final
TRANSCRIPT
8/10/2019 Truck Mtd Conc Pump - Final
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On the job training on
“Truck Mounted Concrete Pumps”
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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.
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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
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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
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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.
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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.
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OPERATING PROCEDURES
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.
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OPERATING PROCEDURES
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.
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OPERATING PROCEDURES
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.
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OPERATING PROCEDURES
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.
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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.
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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.
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(ROCK VALVE TYPE)
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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.
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CLEANING AFTER CONCRETING
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.
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CLEANING AFTER CONCRETING
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.
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CLEANING AFTER CONCRETING
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.
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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.
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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
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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.
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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.
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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)
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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.
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
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
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Schwing BPL580-18/KVM28-24concrete placing pump and boom
• Capacity of oil tank : Approx.480
L
• Capacity of water tank : Approx.500
L
• Capacity of charching hopper : Approx.500
L
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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.
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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.
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Putzmeister BPF 08/M24Concrete placing pump & boom
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
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Putzmeister BPF 08/M24Concrete placing pump & boom
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
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Putzmeister BPF 08/M24Concrete placing pump & boom
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
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Putzmeister BPF 08/M24Concrete placing pump & boom
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.
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Putzmeister BPF 08/M24Concrete placing pump & boom
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
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Putzmeister BPF 08/M24Concrete placing pump & boom
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
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CONCRETE BOOM PLACER
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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
Maintenance schedule Contd
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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
Maintenance schedule Contd
i
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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