Construction Stationary Pump

SANY
PRODUCT TRAINING
CONCRETE PUMP AND PUMPING SYSTEM
2009-11-15 CONCRETE PUMP & PUMPING 1

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Mechanization in Construction and Civil Engineering
Background, Developments and Trends

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TWO EXTREMES – physically almost identical, but so different!
Cheop‘s Pyramid, Gizeh, Egypt Luxor Hotel, Las Vegas USA

Built: ca. 2000 BC Built: 1993 AD
Project duration: approx. 80 years Project duration: approx. 18 months
Workers: up to 100,000 (average 40,000) Workers: 1,500 (on 24/7 routine)
The world‘s tallest structure up to turn of The world‘s most spectacular hotel and
20th Century one of the largest with 2,500 rooms.
Data: 150 m high, 216 x 216 m base Data: 142 m high, 190 x 190 m base

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The Cheop‘s pyramid is make up of some 2,300,000 lime stone block,

weighing averagely 2.5 ton each (some weighs up to 16 ton).
It was built probably using man power and “ramp technology“ available at
that period of time. Most of the stone blocks had to be brought hundreds of
miles from remote quarries and then man-handled 3 or 4 times before they
even got to the “jobsite“.

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The Luxor Hotel was built using state-of-the-art architectural and civils technology
to form a “hollow pyramid“ with the hotel rooms only on the outside walls. The
“inner pyramid“ is a hollow space with areas for restaurants, shopping malls,
“adventure simulators“, theatres and the inevitable Las Vegas slot machines and
casinos!
In-situ poured concrete, pre-fab concrete slabs, sprayed concrete and many types
of rendering and plaster were fully utilized on the $ 365 m project.

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Two fantastic projects that provided an insight into what happens in the world.
Building is no longer a physical exercise!
Building and civils are nowadays “fast-track industries“ running on fixed deadlines.
Principle:“The sooner my building is occupied, or my bridge or tunnel is
operable, the sooner people can move in and the sooner I realize my return on
investment in the form of rents and tolls!“

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What is fast-track building?

Basically, it is industrialized building.
It is making the use of “flexible“ materials ......... naturally rigid and load-
bearing materials, but flexible in the manner that the essentials can be
easily transported and utilized at the place of installation = the jobsite.
It is easy to pre-fabricate a steel-girder bridge in a steel fabrication shop. But

that is not much use if my jobsite is in the Himalayas!
How do I get the girders from shop to site?

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Industrialized building was born with the discovery of Portland

Cement.
From then on it was possible to mix strong, load-bearing concrete
and to utilize it as the world‘s major building material practically
anywhere in the world.
All it needs is the supply of cement and an on-the-spot supply of
sand/aggregate and water.
But even then, things can be improved on.
The fast-track method can be accelerated even further by using

suitable machinery and systems.

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For “industrial
building“ we
need a material
that is easy to
transport, easy
to place and
can be
produced
anywhere in
the world.

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What is concrete?
It is man-made rock.
That is all.
Nothing more.
Nothing less.

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Coarse sand Coarse

aggregate
Fine sand
Fine
aggregate
Cement lime /
fines / ash

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But the value-added advantage of concrete and

especially what is nowadays referred to as
readymix means that we do not have to pull,
push or lift our “man-made rock“ (like the
Egyptians had to pull their stone blocks).
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Because it is “flexible“ we can mix it on site (or

remotely) and pour it into place using a pump.

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We all run concrete

pumps of one type of
another. Perhaps it‘s
an old machine,
perhaps it‘s a very
new, very expensive
one.
But whatever the
type or size of pump,
what we don‘t want is
......
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... a plugged pipe.

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In order to avoid plugging our pipe, we must

understand first a little bit about how concrete
actually flows.
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How does concrete “flow” through the pipe?

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The sponge effect. When pressure is applied, water comes out of the sponge.

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Just like the sponge, when pressure is applied to the concrete, cement
lime (with fines) is pushed out to the pipe wall. This lubricates the flow
of concrete through the pipeline.

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A leaking coupling/seal. Cement lime escapes. Collar of

hard material builds up at C.

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A leaking spectacle.
Cement lime escapes.
Collar of hard material
builds up.

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A bath of water. The steel and the stone sink. Wood floats.

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A bath of thick oil. The steel sinks. The stone is 1/2 and 1/2. The
wood lies on the surface.

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As long as the mix (cement + fines + water) is thick enough,

stones will remain “floating” and can be transported.

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If the concrete mix is too lean, stones settle

to the bottom and jam the pipe.
If lubricant (cement+water+fines) is lost, the

result is the same. A valve jam.
If water bleeds off the concrete, the result is

also the same.

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Gradually rising grade curve

Basic material of the concrete
Passing
In % by
weight.
Mesh size in mm
Grading curve of grain mixture with max grain size aggregate of 16mm and
distribution of the individual grain sizes – grading curve C16

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A well designed mix will have sufficient amounts of large, medium, small
and fine particles. And this will keep the concrete nicely held together.

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TYPES OF CONCRETE PUMPS
1. PISTON PUMPS
2. PNEUMATIC PUMPS
3. SQUEEZE-PRESSURE PUMPS

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PISTON PUMPS
Main components of the piston pump consist of the following:

1. A receiving hopper for mixed concrete.
2. Inlet and outlet valve.
3. Piston rams.
4. Differential and pumping cylinders

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PNEUMATIC PUMPS
Main components of a pneumatic pump consist of:

1. Pressure vessel
2. External air compressor

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SQUEEZE – PRESSURE PUMPS
Main components of a squeeze-pressure pump consist of:

1. A receiving hopper with three remixing blades.
2. A flexible hose connected to the bottom of the hopper.
3. A pumping chamber under a vacuum of 0.8N/mm2.
4. Planetary drive and rotating rollers.

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MAJOR BRANDS IN OUR MARKET
SANY

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SELECTION OF MODELS
Concrete pumps can be classified

either as:
1. Truck mounted pumps
- with extendable placing boom.
- without extendable boom.
2. Stationery or Trailer mounted

pumps.
- mounted on platforms or skids
- mounted on a rubber tire
undercarriage.

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ADVANTAGES AND DISADVANTAGES OF BASIC MODELS
ADVANTAGES OF TRUCK-MOUNTED BOOM DISADVANTAGES OF TRUCK-MOUNTED BOOM

PUMP PUMP
Easier transport of pump and line Higher initial investment cost
Faster set-up on the job
Quicker relocation or repositioning
Better adaptability to changes in lift or

reach requirements
Faster clean-up after use

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ADVANTAGES OF TRUCK MOUNTED PUMP W/O DISADVANTAGES OF TRUCK MOUNTED PUMP

BOOM W/O BOOM
Small initial cost for basic unit Longer and more costly set up time due
to time and labour required to install or
Lower overall transport height, length assemble the pump line and connect line
and weight to the pump
Can use smaller and less expensive truck

chassis

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ADVANTAGES OF STATIONERY PUMPS DISADVANTAGES OFSTATIONERY PUMPS
Lowest initial cost Longer and more costly set up time due
to time and labour required to install or
Lighter weight/ capacity, ratio assemble the pump line and connect
line to the pump
Smaller size and weight permit lifting to

upper stories and use in series for high
lifts
Occupy smaller space on crowded site
Usually require less maintenance and

permit faster clean up

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For years now, the industry has known 4 major systems:
The SCHWING gate valve –

THE valve for rough mixes!
The Putzmeister
ELEPHANT TRUNK – a
system without a system!

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The S-tube – a system adopted

by most concrete pump
manufacturers in the market.
AND
The ROCK – the 3rd of the 4

systems originating at
SCHWING – and the only
system purpose designed with
jobsite requirements in mind!

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WHAT DO CUSTOMERS LOOK FOR WHEN PURCHASING A CONCRETE PUMP.
OBVIOUSLY CUSTOMERS HAD DONE THEIR OWN RESEARCH AND HOMEWORK

BEFORE HAND.
CUSTOMERS ARE GOING TO ASK FOR GOOD BARGAINS.
CUSTOMERS WANT ASSURANCE ON SERVICE BACK UP AND TROUBLE FREE

PUMPING.
A GOOD BARGAINED PRICE IS ONE THING, BUT A GOOD BARGAINED PUMP IS

DIFFERENT.
WHEN PRICE IS AN ISSUE, SOMETIMES IT IS GOOD TO PONDER OVER THE

FOLLOWING:
THERE ARE GOOD PUMPS AT GOOD PRICES
GOOD PUMPS AT FAIR PRICES
FAIR PUMPS AT GOOD PRICES
FAIR PUMPS AT FAIR PRICES
SO BEYOND PRICE, WHAT IS THE DIFFERENCE?????

SUMMED UP TO ONE WORD……………………………………DEPENDABILITY

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DEPENDABILITY can be affected by the following possible causes:
Mechanical failure of the pump, or
Failure to supply a pumpable concrete mix, or
An accidental stoppage caused by oversize aggregates in the line
Concrete left in the mixer too long
Too much water added by the operator
Operator failure or inexperience
Pump and / or line not properly cleaned before use

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SOME COMMON CAUSES OF PUMP STOPPAGE DURING

PUMPING
A plug in the line or in the pump. (not always the

pump’s fault)
Hydraulic pump failure.
Concrete piston seal failure.
Electrical system failure.
Piston failure.
Miscellaneous mechanical or hydraulic failures.

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Concrete Pipeline, Accessories And

Cleaning System

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Standard length of straight concrete pipe : Our range of pipe bend & elbow :
i. 3,000mm i. DN125 x 15º bend x R1000
ii. 2,000mm ii. DN125 x 15º bend x R500
iii. 1,000mm iii. DN125 x 45º bend x R1000
iv. 500mm iv. DN125 x 45º bend x R500
Standard internal dimension of straight pipe: DN125 v. DN125 x 45º elbow x R275
(125mm Ø or 5” Ø)
vi. DN125 x 90º bend x R1000
Our range of wall thickness straight pipe : 4mm & 6mm
vii. DN125 x 90º bend x R500
Materials : Abrasion resistant non-hardened pipe. In
viii. DN125 x 90º bend x R275
case of SANY, the material of concrete pipe is Alloy
Steel. Couplings :
End types : i. Snap coupling – are also referred to as “easy-
open” or “quick-release” couplings. The pressure
i. Hevi-Duty – Designed for moderate to high
ratings are lower than one-bolt coupling. A
pressure (1500 to 2500 psi) service.
safety pin is utilized to prevent the inadvertent or
ii. Metric – Designed for moderate pressures of accidental opening of the coupling.
1000 to 1500 psi.
ii. One Bolt Couplings – uses identical castings as
the snap coupling, except the handle and toggle
mechanism is eliminated. It has a lower pressure
rating than two bolt coupling.

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iii. Working Pressure for 5” Couplings:

Hose – Rubber hose is frequently used in concrete
End type One Bolt Snap placing because it is flexible and lets workers place the
concrete exactly where needed.
Hevi-Duty 2,200 psi 1,500 psi
i. Steel Reinforced Discharge Hose – Used at the
Metric 1,300 psi 1,000 psi point of placement, the flexible steel ply
construction allows easy handling with a small
1. Working pressure based on 3:1 Safety Factor.
bend radius, yet the hose is extremely crush
2. Values are typical for 5” ID system only.
resistant. Steel reinforced discharge hoses utilize
3. Working pressure is for new system when installed and adjusted properly. a 3:1 safety factor, and are typically
4. External mechanical forces reduce coupling working pressure capabilities. recommended for up to 750 psi working
Reducers – Reduces are tapered sections of pipe. pressure.
They are installed between the pump outlet and the ii. Steel Reinforced Boom Hose – This hose is
placement line, between system components with extremely tough and recommended for extreme
different diameters. To minimize the necessary conditions. The steel ply design of the boom
pumping pressure and the potential for blockage within hose eliminates kinking and collapsing of the
the reducer, it is recommended that the reduction be hose and allows easy cleaning by reverse
made as gradual as possible. Typical guidelines are pumping. Boom hoses are typically
one inch of reduction over 4 feet of system. Greater recommended for up to 1000 psi working
reduction rates (shorter reducers) may be possible if pressure at a 3:1 safety factor.
the concrete has good pumpability. The concrete
accelerates going through the reducer, producing a
higher velocity, more turbulence, and therefore more
wear at the reducer outlet.

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Brackets – Concrete pumping lines must be securely There are two types of shut off valve:
anchored to minimize movement. Movement in the
Sliding shut off valve
pipeline reduces pump output, and causes system parts
to wear and fatigue at the coupling joints. Coupling Hydraulic shut of valve
fracture and system separation can occur. There are a
iii. Discharge Valves – These valves allow concrete
variety of brackets which can be used to secure the line
to be discharged at various locations along the
quickly and safety to structural steel sections or to
pipeline. They are particularly useful for large
concrete decks or walls. The brackets selected must be
wall pours when the forms must be filled in
strong enough to support the size and weight of the
several layers or lifts. Typically valves are
pipe, and should be adjustable for various job
installed 8 to 10 feet apart, allowing the concrete
conditions.
to flow into the top of the form. Closing the valve
Valves – There are a wide variety of valves available to allows the concrete to flow through the line into
divert, dump, or stop the flow of concrete. Some of the the next open valve. When specification limit the
valves are manually operated, while others are distance that concrete may free fall, tremies can
hydraulically actuated. The valves are classified by be attached to the discharge valve openings. A
function into three types: hopper with a tremie attached must be placed
below the discharge opening of the valve if free –
i. Diversion Valves – These valves split the line
fall must be limited.
system into multiple lines and control the
direction of flow.
ii. Shut off valve – Shut off valves stop the flow of
concrete within the pumping system. They either
insert an obstruction into the concrete flow, or
shift one line relative to the second line.

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Clean Out Accessories

i. Go-Devil or Ball – The go-devil is made of hard The devil catcher must be long enough to allow
rubber and is very effective in cleaning out longer all the cleanout devices (go-devil, balls, etc) or
line systems. Because it is elongated and rigid, it combination of devices to exit the pipeline.
may hang up in short radius elbows. Wash-out
iii. Blow-Out Cap (Air Blower) – The appropriate
balls are made of hard sponge rubber, soft
type of blow out cap must be utilized. A water
sponge rubber, or urethane foam. Soft balls are
cap has only a single valve and inlet port. An air
designed for use when blowing out lines with
blow out cap must have a separate bleed off
water or when sucking the ball back. The hard
valve to allow the operator to relieve pressure in
balls are designed for cleaning out lines with air.
the system. Relieving the line air pressure allows
Urethane foam balls can be used to clean out
the operator to control the movement speed of
boom lines and are soaked in oil prior to use.
the concrete or to disconnect the line safety if
All cleanout devices are larger in diameter than required.
the lines in which they are used. They are
compressed before being inserted into the pipe
to ensure a tight fit. A tight fit is absolutely
necessary to retain air or water pressure.
ii. Devil Catcher (Ball Catcher) – The devil catcher
is installed at the point of cleanout discharge. It
catches the ball or go-devil upon release, while
allowing the concrete to pass through
unimpeded.

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TECHNICAL IDENTIFICATION NUMBER

Power supply: TK = P x25
TK
Consumption: TK= Q x p
TK = Q x p = P x 25
You know the
Q = Concrete Output (m³/h)
pressure
p = Concrete pressure (bar)
and ask for output:
P = Working power (kW)
Q=TK
P
You know the

(P) Power (kW)= TK = m³/h x bar
output
25 25
and you ask for the
Pressure:
p=TK
2009-11-15 CONCRETE PUMP & PUMPING Q 49
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How to use the nomograph to ascertain concrete
pressure.
Our job: to pump 40 m3/h (No. 1) through 125

mm line (No. 2), 262 m long (No. 3), concrete 2
slump 10 cm (No. 4), vertical rise 189.2 m = 47.3
bar compensation (No. 5). 1
The result is
88.3 bar 5
3
4

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PHOTOGRAPHS SHOWS LAYING AND ANCHORING OF PIPE LINES

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Setting up the pump and pipeline
Ground line secured in concrete blocks,

especially at corners (horizontal and
vertical)
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Riser pipeline secured at least

every second pipe section.
Long-radius riser bend

secured in concrete.

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Blow-out head for air/water ready for cleaning out procedure.

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A very simple, very effective diversion valve. Loosen the clip, swing
over the bend and connect again to change concrete flow from
right to left.

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These pipelines are not well layed. They both cause

extra stress on the pump.
Flanges/couplings suffer. Blockages are the result

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? ?
Another bad example. 1st pipe not supported. 2nd pipe not supported. 3rd pipe only lying on steel
trestle. 4th pipe only fastened with wire to concrete block.

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SAFE COUPLINGS – NO WAY!

These are accidents looking for
somewhere to happen!
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An end hose is also

needed. But NOT this
type, and NOT with
this type of “clip“!
This isn‘t an end

hose either!
?
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Whatever happens, this is what the contractor does NOT

want
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Or that……..????

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Scissors and compensators
Scissors and compensators are used to let the pipeline pivot or

rotate and to lengthen or shorten even while concrete is flowing
through it. Shown here a scissor arrangement on a barge at
Potsdamer Platz, Berlin.
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Pipelines come from the bankside to the first 3-D compensators

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Then over the “pontoon bridges“ to the

radial distributors and then down into the
water where the divers are working.

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Very simple,
very effective
“continuous“
scissors
mounted on
surplus
Alimak mast
sections

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Project Reference
The world tallest super tower in the making – Burj Dubai,

twenty over units SANY concrete pumps are used to deliver
the job in concreting.
Project value: USD$20 billion.
No of floors: 160
Height of building: >700m

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Project Reference
Duobaokeng Tunnel of Meikan Railway Guiyang Water Diversion Project （42 m

（pumping horizontally 1150 m at the furthest ） downward pumping and consequent 700 m
horizontal pumping ）

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Project Reference
Saige Square of Shenzhen ，the domestic

Financial
records of 300.8 m of vertical upward pumping,
Center of
1998
Hongkong 420m
high，rewritten
by itself in
Hongkong in
2001 with the
world records of
vertical upward
pumping created

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END OF PRESENTATION
SANY
THANK YOU
SYSTEM

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SANY

CONCRETE PUMP AND PUMPING SYSTEM

2009-11-15 CONCRETE PUMP & PUMPING 1

Mechanization in Construction and Civil Engineering

Background, Developments and Trends

2009-11-15 CONCRETE PUMP & PUMPING 2

TWO EXTREMES – physically almost identical, but so different!

Cheop‘s Pyramid, Gizeh, Egypt Luxor Hotel, Las Vegas USA

2009-11-15 CONCRETE PUMP & PUMPING 3

The Cheop‘s pyramid is make up of some 2,300,000 lime stone block,

2009-11-15 CONCRETE PUMP & PUMPING 4

2009-11-15 CONCRETE PUMP & PUMPING 5

2009-11-15 CONCRETE PUMP & PUMPING 6

What is fast-track building?

It is easy to pre-fabricate a steel-girder bridge in a steel fabrication shop. But

2009-11-15 CONCRETE PUMP & PUMPING 7

Industrialized building was born with the discovery of Portland

The fast-track method can be accelerated even further by using

2009-11-15 CONCRETE PUMP & PUMPING 8

2009-11-15 CONCRETE PUMP & PUMPING 9

2009-11-15 CONCRETE PUMP & PUMPING 10

Coarse sand Coarse

2009-11-15 CONCRETE PUMP & PUMPING 11

But the value-added advantage of concrete and

Because it is “flexible“ we can mix it on site (or

2009-11-15 CONCRETE PUMP & PUMPING 13

We all run concrete

... a plugged pipe.

2009-11-15 CONCRETE PUMP & PUMPING 15

In order to avoid plugging our pipe, we must

How does concrete “flow” through the pipe?

2009-11-15 CONCRETE PUMP & PUMPING 17

2009-11-15 CONCRETE PUMP & PUMPING 18

2009-11-15 CONCRETE PUMP & PUMPING 19

A leaking coupling/seal. Cement lime escapes. Collar of

2009-11-15 CONCRETE PUMP & PUMPING 20

2009-11-15 CONCRETE PUMP & PUMPING 21

2009-11-15 CONCRETE PUMP & PUMPING 22

2009-11-15 CONCRETE PUMP & PUMPING 23

As long as the mix (cement + fines + water) is thick enough,

2009-11-15 CONCRETE PUMP & PUMPING 24

If the concrete mix is too lean, stones settle

If lubricant (cement+water+fines) is lost, the

If water bleeds off the concrete, the result is

2009-11-15 CONCRETE PUMP & PUMPING 25

Gradually rising grade curve

2009-11-15 CONCRETE PUMP & PUMPING 26

2009-11-15 CONCRETE PUMP & PUMPING 27

TYPES OF CONCRETE PUMPS

2009-11-15 CONCRETE PUMP & PUMPING 28

Main components of the piston pump consist of the following:

2009-11-15 CONCRETE PUMP & PUMPING 29

Main components of a pneumatic pump consist of:

2009-11-15 CONCRETE PUMP & PUMPING 30

SQUEEZE – PRESSURE PUMPS

Main components of a squeeze-pressure pump consist of:

2009-11-15 CONCRETE PUMP & PUMPING 31

MAJOR BRANDS IN OUR MARKET

Easier transport of pump and line Higher initial investment cost

Faster set-up on the job

Quicker relocation or repositioning

Better adaptability to changes in lift or

Faster clean-up after use

Can use smaller and less expensive truck

Smaller size and weight permit lifting to

Occupy smaller space on crowded site

Usually require less maintenance and

OBVIOUSLY CUSTOMERS HAD DONE THEIR OWN RESEARCH AND HOMEWORK

CUSTOMERS ARE GOING TO ASK FOR GOOD BARGAINS.

CUSTOMERS WANT ASSURANCE ON SERVICE BACK UP AND TROUBLE FREE

A GOOD BARGAINED PRICE IS ONE THING, BUT A GOOD BARGAINED PUMP IS

WHEN PRICE IS AN ISSUE, SOMETIMES IT IS GOOD TO PONDER OVER THE

SO BEYOND PRICE, WHAT IS THE DIFFERENCE?????

Mechanical failure of the pump, or

Failure to supply a pumpable concrete mix, or

An accidental stoppage caused by oversize aggregates in the line

Concrete left in the mixer too long

Too much water added by the operator

Operator failure or inexperience

Pump and / or line not properly cleaned before use

A plug in the line or in the pump. (not always the

Clean Out Accessories

You know the