Pumped Concrete

CONTENTS

1.) INTRODUCTION 2.) Types of Truck 1. Boom or Truck Mounted Pump 2. Tr !"er# "!ne or st t!on ry pump 3. $pec! "!%ed us &e pump 3.) () t re t)e d* nt &es !n us!n& Concrete Pump Trucks+ '.) ,o- Does Concrete Pump Truck -ork+ ..) Proper $!%!n& of /!nes nd 01u!pment 2.) C)oos!n& t)e Proper ,ose 1. /!ne D! meter 2. /!ne /en&t) 3. P!pe"!ne / yout 3.) ,o- Concrete Mo*es T)rou&) t)e Pump /!ne 4.) Proper Truck Pos!t!on!n& 1. Po-er /!nes 2. 05c * t!ons 3. Ot)er O6struct!ons 7.) $t 6!"!%!n& t)e Pump Truck 18.) 11.) P" c!n& t)e Boom B"o-out Pre*ent!on 1. /oc t!n& B"ock &e

3 3 3 3 ' ' . . 2 2 2 2 3 3 4 4 4 7 7 18 11
1

Pumped Concrete

2. C"e r!n& t)e B"ock &e

1. T)e (ron& M!5 2. Pro6"ems -!t) t)e P!pe"!ne 3. Oper tor 0rror

12 12 12 13 13 1' 1'

12.) 13.)

C)eck!n& for (e r $ecur!n& t)e $ystem 1. C"e n!n& t)e $ystem

Pumped Concrete

1.) INTRODUCTION 9 concrete pump !s n !mport nt p rt of ny construct!on pro:ect. Pump!n& !s eff!c!ent nd re"! 6"e me ns of p" c!n& concrete# -)!c) m kes !t pump !s t)e on"y - y of p" c!n& concrete !n *ery

*ery econom!c " met)od s )!&) r!se 6u!"d!n&# or

-e"". It !s used !n tr nsferr!n& "!1u!d concrete 6y pump!n& !t to t)e construct!on s!te. $omet!mes# cert !n "oc t!on. $uc) s " r&e s" 6s -)ere t)e c)utes of t)e concrete truck c nt re c) -)ere t)e concrete !s needed. Ot)er t!mes# t)e e se nd speed of pump!n& concrete m kes !t t)e most econom!c " met)od of concrete p" cement. 2.) Types of Truck T)ere re m !n"y t)ree types of concrete pumps;

Boom or truck mounted pump Tr !"er# "!ne# or st t!on ry pump $pec! "!%ed us &e pump

/et<s 6r!ef"y "ook t t)ese t)ree types of pumps. 2.1) Boom or Truck Mounte !ump T)!s type of pump !s tt c)ed to kno-n s truck nd uses remote contro""ed rt!cu" t!n& ro6ot!c

rm# "so kno-n s 6oom# to p" ce t)e concrete ccur te"y t t)e construct!on s!te. It !s "so truck mounted 6oom pump. Boom pumps re &ener ""y used !n " r&e construct!on pro:ects 6ec use of !ts c p 6!"!ty of pump!n& )!&) *o"ume of concrete !n "ess t!me. It "so s *es su6st nt! " " 6or 6ec use of !ts mu"t!=purpose ro6ot!c rm. 2.2) Tr"#$er% $#ne or st"t#on"ry pump T)!s type of pump !s mounted on tr !"er nd re1u!res stee" or ru66er )oses to 6e

tt c)ed to t)e out"et of t)e m c)!ne. T)e )oses re &ener ""y m nu ""y tt c)ed nd c n "so 6e :o!ned to not)er e5tens!on )oses to re c) t)e ppropr! te s!te -)ere t)e concrete needs to 6e put. Tr !"er pumps pump concrete t r te "o-er t) n t) t of 6oom pumps nd t)erefore re used
3

Pumped Concrete

!n pp"!c t!ons t) t re1u!re sm ""er *o"ume pump!n& suc) s s-!mm!n& poo"s# s!de- "ks# nd sm "" )omes concrete s" 6s. 2.3) Spec#"$#&e us"'e pump T)ese pumps re spec!f!c ""y m de for spec! "!%ed :o6 s!tes suc) s m!nes nd tunne"s. T)ey re "so sk!d mounted nd r !" mounted concrete pumps 6ut re not common"y used due to t)e!r )!&) costs nd e5tr spec! "!%ed mec) n!sm. (.) )*"t "re t*e " +"nt"'es #n us#n' Concrete !ump Trucks,

Pump!n& p" cement !s f ster t) n p" cement 6y ot)er met)ods >-)ee"6 rro-# t !"& t!n&# or sk!dster "o der) Pumped concrete c n 6e p" ced !n re s t) t re d!ff!cu"t or !mposs!6"e to re c) 6y ot)er p" cement met)ods.

Pump!n& often resu"ts !n s *!n&s !n m npo-er# e1u!pment cost nd cyc"e t!me. Pump!n& c n t ke p" ce under ny -e t)er cond!t!ons# !nc"ud!n& sno- nd r !n# s!nce t)e concrete !s protected from t)e e"ements dur!n& tr nsport to t)e p" cement re .

Pump!n& c n 6e used -)en t)e sp ce * !" 6"e for construct!on e1u!pment !s "!m!ted. Pump!n& concrete frees cr nes nd )o!sts for ot)er construct!on oper t!ons# suc) s de"!*er!n& m ter! "s.

Pumped concrete c n 6e e s!er to ) nd"e 6ec use t)e f"o- of concrete !s d!rected to t)e e5 ct spot of p" cement >-)ere s cr nes nd con*eyors depos!t " r&e p!"es of concrete t) t must 6e mo*ed m nu ""y).

?e- o6st c"es c n 6"ock

concrete pump!n& p!pe"!ne. P!pe"!nes c n corner s) rp"y# p ss

t)rou&) n rro- sp ces# tr *e" o*er or under - ""s# etc.

9 cont!nuous supp"y of pumped concrete c n )e"p set p" cement cre-# t)ere6y !ncre s!n& product!*!ty.

ste dy -ork p ce for t)e

Pumped Concrete

9 contr ctor c n * ry t)e p" cement speed or dd "!nes to f!t t)e p ce of t)e :o6. ?"o- of concrete rem !ns ste dy nd contro""ed. Pump!n& concrete ""o-s contr ctor to p" ce f"oor s" 6s on upper f"oors 6efore

comp"et!n& t)e concrete -ork on "o-er f"oors. T)!s pro*!des protect!on from -e t)er -)en -ork!n& on "o-er f"oors. -.) .o/ Does " Concrete !ump Truck /ork, 9 concrete m!5er truck 6 cks up to t)e 6 ck of p!pe# forc!n& t)e concrete t)rou&) pump truck nd d!sc) r&es !ts "o d !nto

t)e )opper. T)e )opper feeds t)e concrete t)rou&) pump -)!c) pp"!es pressure to co"umn of "u6r!c ted )ose.Concrete pumps re often used to re c) p" ces t) t re d!ff!cu"t or !mposs!6"e to re c) 6y ot)er concrete p" cement met)ods# suc) s 6 cky rd s-!mm!n& poo"s or )!&)=r!se 6u!"d!n&s. Pump!n& !s "so used -)en t)e sp ce * !" 6"e for construct!on e1u!pment !s "!m!ted. 9ppro5!m te"y 1@' of "" concrete p" ced !n t)e Un!ted $t tes !s p" ced 6y concrete pump!n& 0.) !roper S#&#n' of 1#nes "n E2u#pment In order to opt!m!%e t)e concrete pump!n& oper t!on# t)e most eff!c!ent conf!&ur t!on of t)e system must 6e determ!ned. 9 spec!f!c "!ne pressure must 6e determ!ned to mo*e concrete t spec!f!ed r te f"o- t)rou&) ffect!n& p!pe"!ne pressure re;

p!pe"!ne of

p rt!cu" r "en&t) nd d! meter. T)e m :or f ctors

Pump!n& r te /!ne d! meter ,or!%ont " nd *ert!c " d!st nces Conf!&ur t!on# !nc"ud!n& reduc!n& sect!ons num6er of ot)er f ctors must 6e t ken !nto ccount -)en determ!n!n& "!ne

In dd!t!on#

pressure# !nc"ud!n&;
5

Pumped Concrete

T)e *ert!c " r!se T)e num6er nd se*er!ty of 6ends T)e mount of f"e5!6"e )ose used !n t)e "!ne

0.1) C*oos#n' t*e !roper .ose ,oses re m nuf ctured for spec!f!c pp"!c t!ons# nd us!n& t)e proper )ose for t)e proper pp"!c t!on !s p r mount for s fety on t)e concrete pump!n& s!te. ,ose des!&n ted s d!sc) r&e type s)ou"d 6e used on"y t po!nt of p" cement for d!sc) r&e. 9s ru"e of t)um6 ne*er use d!sc) r&e )ose !n "ess t) n 2'=!nc) r d!us. ?or 6oom truck pp"!c t!ons# 6oom )ose !n "ess t) n spec! ""y 38=!nc) re!nforced )ose !s recommended. Ru"e of t)um6; Ne*er use r d!us.

0.2) 1#ne D#"meter In &ener "# t)e " r&er t)e !ns!de d! meter of t)e p!pe"!ne# t)e "ess pressure re1u!red to mo*e t)e concrete t)rou&) t)e p!pe"!ne t &!*en r te. T)ere !s m :or dr -6 ck to " r&e= d! meter p!pe"!nes )o-e*er; t)e " r&er t)e "!ne# t)e more " 6or# 6"ock!n& nd 6r c!n& !t -!"" re1u!re. 9s ru"e of t)um6% t)e m 5!mum s!%e &&re& te s)ou"d 6e no more t) n one=t)!rd t)e !ns!de d! meter of t)e de"!*ery system.

0.3) 1#ne 1en't* ?r!ct!on 6et-een t)e pumped concrete nd t)e !ntern " p!pe"!ne - "" me ns t) t t)e "!ne "en&t) d!rect"y ffects t)e "!ne pressure re1u!rement. T)e "on&er t)e p!pe"!ne "en&t)# t)e more stee" p!pe# -!t) !ts smoot) !nter!or surf ce# 6ecomes des!r 6"e. )e#'*#n' t*e opt#ons3

T)e con*en!ence of e sy ccess for truck m!5ers must 6e -e!&)ed & !nst t)e des!r 6!"!ty of "oc t!n& t)e pump c"oser to t)e p" cement po!nt.
6

Pumped Concrete

Cons!der us!n& t-o "!nes nd t-o pumps -)en t)ere !s " r&e d!st nce 6et-een t)e pump nd t)e furt)est p" cement po!nt. T)e end of t)e f!rst pump feeds !nto t)e )opper of t)e second pump. T)!s m y oper te more eff!c!ent"y t) n e5cess!*e "!ne s!n&"e system oper t!n& t

0.() !#pe$#ne 1"yout ?or t)e "e st "!ne res!st nce# t*e p#pe$#ne s*ou$ cont"#n " m#n#mum num4er of 4en s . T)!s !s 6ec use t)ere !s n !ncre sed res!st nce to mo*ement of t)e concrete correspond!n& to n !ncre sed num6er of c) n&es !n "!ne d!rect!on. Reduct!ons !n p!pe d! meter -!t)!n t)e s me "!ne "so !ncre ses res!st nce# so t)e s me d! meter "!ne s)ou"d 6e used t)rou&)out -)ene*er poss!6"e. If t)e d! meter must 6e reduced -!t)!n t)e "!ne# reducers s)ou"d 6e used. T)e "on&er t)e reducer t)e 6etter; !t t kes f r more ener&y to pump concrete t)rou&) t) n !t does one e!&)t feet "on&. reducer four feet "on&

5.) .o/ Concrete Mo+es T*rou'* t*e !ump 1#ne ()en concrete !s pumped t)rou&) t)e pump "!ne# !t !s sep r ted from t)e pump "!ne - ""s 6y "u6r!c t!n& " yer of - ter# cement nd s nd. N tur ""y# t)e concrete m!5 must 6e su!t 6"e for !ts p rt!cu" r pp"!c t!on# 6ut !t must "so cont !n enou&) - ter for t)e m!5 to mo*e e s!"y t)rou&) t)e reducers# 6ends nd )oses found !n most 6 s!c p!pe"!ne setups. It !s !mport nt to ) *e "" concrete m!5es spec!f!ed s Apump 6"eA pr!or to ny concrete pours. T)ere re m!5es t) t do not pump t "" or c use t)e pump "!nes to c"o&= 6!& pro6"ems !f you ) *e 4 trucks rr!*!n& on t)e :o6 re dy to d!sc) r&e concrete

6.) !roper Truck !os#t#on#n' T)e pr!m ry concern -)en ut!"!%!n& pump truck dur!n& pumped concrete pour !s

s fe"y pos!t!on!n& t)e truck -)ere t)e 6oom c n re c) t)e concrete p" cement s!te. T)e key -ord )ere !s As fe"y.A Improper"y pos!t!oned# pump truck c n c use de t) or ser!ous !n:ury# m k!n& n!&)tm re out of -) t m y ) *e ppe red to 6e st nd rd# Ae*ery d yA pour. T)e pump!n& cre7

Pumped Concrete

c n on"y ut!"!%e t)e pump truck nd 6oom -)en t)e cond!t!ons re ent!re"y s fe. Pr!or to e5tend!n& t)e pump truck 6oom on ne- :o6 s!te# c)eck for t)e fo""o-!n&; Po-er "!nes 05c * t!ons Ot)er o6struct!ons

6.1) !o/er 1#nes T)e truck 6oom# c) ss!s# remote=contro" c 6"e# nd stee"=6r !ded end )ose re &re t conductors of e"ectr!c!ty. 9nd -!t) !ts )!&) - ter content# t)e concrete !tse"f c n 6ecome de t)"y e"ectr!c condu!t !f ny p rt of t)e pump m c)!nery comes !n cont ct -!t) po-er "!nes. T)!s !s -)y more concrete pump oper tors d!e from e"ectrocut!on t) n ny ot)er :o6=re" ted c use. 9nd e*en t)e ru66er 6oots or ru66er=so"ed -ork6oots -orn 6y concrete -orkers -ont protect t)em from t)e 4#888 *o"ts most res!dent! " po-er "!nes c rry !f t) t -orker !s !n cont ct -!t) ny p rt of t)e e1u!pment t) t touc)es po-er "!ne. , "f of "" cc!dents !n*o"*!n& 6ooms nd po-er "!nes ) ppen -)en t)e m c)!ne !s 6e!n& fo"ded# unfo"ded or remo*ed. T)!s !s -)y O$,9 recommends p" c!n& fu""=t!me spotter !n pos!t!on to keep n eye on t)e 6oom !t !ts t "" poss!6"e to !n d*ertent"y )!t n e"ectr!c -!re. T)e 9mer!c n Concrete Pump!n& 9ssoc! t!on re1u!res t) t t)e 6oom t!p nd ny ot)er sect!on of t)e 6oom 6e t "e st 13 feet >. meters) from po-er "!nes.

6.2) E7c"+"t#ons Remem6er t)e Aone=to=oneA ru"e -)en pump!n& concrete ne r n e5c * t!on or " nd t) t f ""s off steep"y from t)e pump; ?or e*ery foot of dept)# pos!t!on t)e pump t "e st one foot 6 ck from t)e ed&e. Pumps c n 6e p" ced c"oser to t)e ed&e of !nst nce# on s"ope t) n to *ert!c " drop=off. ?or set6 ck. 9nd c n one=to=one s"ope# t)e pump often does not re1u!re muc) of

often 6e p" ced t t)e top of t)e s"ope. ()en pump!n& !nto n e5c * t!on# t ke !nto cons!der t!on t)e f ct t) t most 6oom pumps ) *e muc) )!&)er up- rd re c) t) n do-n- rd. 9 6oom pump t) t c n re c) 188 feet )!&) m y ) *e on"y 6out ) "f t) t re c) do-n- rd.
8

Pumped Concrete

6.3) Ot*er O4struct#ons O6struct!ons on t)e :o6 s!te ot)er t) n po-er "!nes m y c use pro6"ems# s -e"". P y c refu" ttent!on to o6:ects suc) s cr nes# sc ffo"d!n& or 6u!"d!n&s. M ke sure t)e 6ooms "en&t) nd rt!cu" t!on !s r!&)t for t)e :o6. 9 6oom too s)ort for t)e :o6 m y 6e 6"e to p" ce t)e concrete correct"y# 6ut m y "so 6e too s)ort to c"e r ot)er o6struct!ons.

8.) St"4#$#&#n' t*e !ump Truck (ood nd "um!num p ds nd " yers of 'B'= or 'B2=!nc) 6o rds >c ""ed cr!66!n&) re often used under t)e pump trucks outr!&&ers to spre d out !ts "o d. T)!s re1u!res determ!n!n& t)e "o d 6e r!n& c p c!ty not on"y of t)e so!"# 6ut of t)e cr!66!n&# s -e"". C"$cu$"t#n' !ressures on 9roun Surf"ces :m"t*em"t#c"$) In order to st 6!"!%e t)e concrete pump truck# !t must 6e determ!ned !f t)e proper support !s 6e!n& &!*en for t)e type of surf ce t)e truck !s mounted on. One - y to do t)!s !s to c "cu" te t)e pressure p" ced on t)e so!" 6y e c) of t)e trucks outr!&&ers 6y d!*!d!n& t)e m 5!mum force on t)e outr!&&er "e& 6y t)e re of so!" cont ct. T)e re of so!" cont ct !s e!t)er t)e re of t)e -ood or "um!num p d# or t)e cr!66!n&# !f used# on e c) outr!&&er. T)e pressure from e c) outr!&&er must 6e "ess t) n t)e "o d 6e r!n& c p c!ty of t)e so!". >$ee T 6"e; 9""o- 6"e Pressures for C r!ous $urf ces# 6e"o-) C"$cu$"t#n' !ressures on 9roun Surf"ces :p*ys#c"$) $!nce oper tors often don<t kno- t)e so!"s 6e r!n& c p c!ty# T)!s !n*o"*es " y!n& cr!66!n& on One t !n. 1;.) !$"c#n' t*e Boom p)ys!c " test !s often used.

f!rm spot of &round nd pos!t!on!n& t)e outr!&&ers on t)em. " r&er re of cr!66!n& put

t!me# t)e oper tor e5tends t)e 6oom out o*er e c) outr!&&er# c)eck!n& to see !f t)e

cr!66!n& s!nks. If !t does# !t me ns t)e 6oom must 6e refo"ded# nd

Pumped Concrete

Dept) percept!on -)en :ud&!n& f r - y o6:ects !s se"dom re"! 6"e# nd s)ou"d 6e *o!ded -)en oper tors re p" c!n& t)e!r 6ooms.

Inste" 3 Oper tors s)ou"d use r d!o or c 6"e remote contro" fter pos!t!on!n& t)emse"*es so t)ey c n ccur te"y :ud&e t)e d!st nce 6et-een t)e 6oom nd t)e -!res. T)e 6est p" ce to :ud&e t) t d!st nce !s perpend!cu" r to t)e 6oom# 6et-een t)e p" c!n& re spotter us!n& nd t)e po-er -!res or emp"oy t-o=- y r d!o or ) nd s!&n "s to ss!st t)e oper tor !n m neu*er!n& t)e 6oom !n f" s)"!&)t or spot"!&)t s)ou"d 6e used to c)eck for po-er "!nes. ,o-e*er#

t)e e*ent t)e oper tor c nt "e *e t)e pump. If t)e oper tor !s re1u!red to set up t t)e :o6s!te 6efore or fter d rk# "- ys err on t)e s fe s!de# nd s *e unfo"d!n& t)e 6oom unt!" d y"!&)t !f t)ere !s ny 1uest!on s to t)e e5!stence of po-er "!nes.

11.) B$o/out !re+ent#on B"o-outs !n IC?s re r re# 6ut )ere re some t!ps on reduc!n& t)e r!sk of suc) n occurrence; , *e for ny *o!ds. If t)e *o!d 6y s"!pp!n& -orker cont!nuous"y t p t)e form-ork dur!n& concrete p" cement to c)eck )o""o- sound !n n ot)er-!se so"!d - "" !s detected# d!s"od&e t)e c"o& nd f!"" "on& p!ece of str pp!n& or re6 r !nto t)e concrete from 6o*e# nd s"!de !t

up nd do-n 6o*e t)e *o!d. 9 6u"&e !n t)e form-ork !s - rn!n& s!&n of poss!6"e 6"o-out. In t)!s c se# t)e p" c!n& cre- s)ou"d 6e s!&n "ed to mo*e t)e pour - y from t)e pro6"em re . T)e 6u"&e c n t)en 6e 6r ced -!t) k!cker. In c se of 2B2=foot s1u re of p"y-ood -ed&ed to t)e - "" -!t) -ooden 6"o-out# t)e torn fo m must 6e cut - y# nd t)e concrete scooped out to s1u re of p"y-ood & !nst t)e - ""#

"e*e" 6e"o- t)e 6"o-out. T)en# rep" ce t)e fo m nd set front nd 6 ck# to co*er t)e d m &ed re .

10

Pumped Concrete

11.1) 1oc"t#n' " B$ock"'e Concrete pump!n& cre-s nd t)e concrete pumper must 6e const nt"y - re of t)e poss!6!"!ty of pump "!ne 6"ock &e# or rock : m# nd 6e 6"e to remo*e t)em prompt"y nd s fe"y. C r! t!ons !n t)e m!5# -)et)er too rocky# -et or dry# fore!&n m tter !n t)e m!5 >suc) s o"d concrete t) t ) s 6roken - y from m!5er f!ns# or unm!5ed c"umps of concrete)# nd ot)er m!5 nom "!es re t!p=offs t) t pro6"ems m y ) *e occurred# or m y 6e 6out to occur. 9 r!s!n& !n "!ne res!st nce# s s)o-n on t)e pump pressure & u&e# !nd!c tes "!ne 6"ock &e. T)e f!rst suspect spot for 6"ock &e !s t)e reducer# -)!c) connects t)e concrete pump to t)e p!pe"!ne system. 9 1u!ck 6u!"d=up !n pressure pr!or to t)e : m !nd!c tes t)e 6"ock &e !s most "!ke"y !n t)e pump re . $"o- pressure 6u!"d=up !s !nd!c t!*e of : m furt)er do-n t)e "!ne# ne rer t)e de"!*ery end. T)e oper tor needs to e5 m!ne t)e system# espec! ""y t t)e e"6o-s or d!sc) r&e )ose. T)!s c n 6e done 6y t pp!n& t)e ) mmer "on& t)e p!pe"!ne. ()ere concrete !s : mmed# t)e ) mmer -!"" produce du"" t)ud# s opposed to more r!n&!n& sound -)ere t)e "!ne !s c"e r. 9"" p!pe :o!nts s)ou"d "so 6e !nspected for &rout "e k &e# s -e""# s t)!s c n 6e !nd!c t!*e of &rout "oss nd su6se1uent 6"ock &e. By c refu""y - "k!n& o*er or stepp!n& on t)e d!sc) r&e )ose to depress !t# &&re& te 6"ock &e m y 6e "oc ted -)ere t)e soft )ose 6ecomes f!rm# !nd!c t!n& : mmed

11.2) C$e"r#n' t*e B$ock"'e By "tern te"y re*ers!n& t)e pump nd resum!n& pump!n& for oper tor m y 6e 6"e to 6re k "oose fe- cyc"es# t)e pump

m!nor rock : m. T)!s s)ou"d not 6e tr!ed more t) n

coup"e of t!mes# )o-e*er# s !t c n : m t)e p!pe"!ne e*en t!&)ter. If t)e re*ers " met)od doesn<t -ork# t)e oper tor must "oc te t)e 6"ock &e# t)en 6re k 6 ck t)e "!ne nd c"e r !t out. 9"- ys m ke sure t)e "!ne !s no "on&er under pressure pr!or to c"e r!n& 6"ock &e. $t nd to one s!de of t)e "!ne nd remo*e t)e coup"!n& ne rest t)e : m. /et "" t)e free=f"o-!n& concrete run out of t)e open end of t)e "!ne 6y "!ft!n& t)e "!ne# t)en 6end t)e )ose or t p on t)e p!pe"!ne !n t)e re of t)e : m nd s) ke out "oose p rt!c"es. Import"nt s"fety t#p; -)en try!n& to c"e r "!ne 6"ock &e# N0C0R use compressed !r. If
11

&re t"y !ncre sed pump pressure -ont mo*e t)e 6"ock &e# compressed !r -ont 6e 6"e to e!t)er.

Pumped Concrete

()!"e us!n& compressed !r ut!"!%!n& proper s fety prec ut!ons !s OD for c"e n!n& out un6"ocked sect!ons of p!pe# us!n& !t on 6"ock &es c n c use "" k!nds of pro6"ems# !nc"ud!n& t)e need to re"!e*e t)e 6u!"t=up se&re& t!on. !r pressure# res!du " !r pockets# nd dd!t!on " 6"ock &es due to

11.3) C"uses of B$ock"'es T)ere re 6 s!c ""y t)ree m !n c uses of pump "!ne 6"ock &es; def!c!ency !n t)e m!5 des!&n pro6"ems -!t) t)e p!pe"!ne !tse"f )um n f ctor# or oper tor error.

11.3.1) T*e )ron' M#7 T)e most common m!5 pro6"em !s concrete t) t does not ret !n !ts m!5!n& - ter. Concrete c n 6"eed due to poor"y &r ded s nd t) t ""o-s - ter to 6"eed t)rou&) t)e sm "" c) nne"s formed due to *o!ds !n t)e s nd# or !f t)e concrete !s too -et. Insuff!c!ent m!5!n& c n c use se&re& t!on !n t)e m!5. ?or successfu" pump!n&# &&re& te must ) *e cement &rout to "u6r!c te t)e m!5 s !t !s 6e!n& pumped. 9 de" y !n p" c!n& t)e concrete due to tr ff!c or :o6 s!te pro6"ems# s -e"" s )ot -e t)er cond!t!ons# m y c use t)e concrete to 6e&!n to set prem ture"y. T)!s cre tes pressures. 11.3.2) !ro4$ems /#t* t*e !#pe$#ne T)e ent!re pump!n& system must 6e e* "u ted for t)e :o6 !t !s to perform. Cons!der t!ons !nc"ude proper"y s!%ed system !nc"ud!n& pump c p c!ty nd motor )orsepo-er to mo*e t)e concrete t)rou&) t)e fu"" "en&t) of t)e p!pe"!ne. P!pes t) t ) *e 6een !mproper"y c"e ned m y c use 6"ock &es -)ere o"d concrete ) s set# nd m y c use 6"eed!n& nd se&re& t!on. Defect!*e
12

fu"" co t!n& of

m!5 t) t m y 6e

too st!ff to pump# 6ec use !t -ont f!"" t)e pump!n& cy"!nders# c us!n& e5cess!*e pump!n&

Pumped Concrete

coup"!n&s# & skets# or -e"d co"" rs "so c n resu"t !n t)e "oss of &rout. 9not)er t)!n& to "ook for re 6ends t) t re too s)ort# too s) rp# or too numerous# "" of -)!c) !ncre se concrete pump!n& pressure. C r! t!ons of p!pe"!ne d! meter# suc) s -)en t)rou&) t)e sm ""er d! meter p!pe"!ne. " r&er d! meter )ose !s coup"ed -!t) sm ""er one# m y c use 6"ock &es or rock : ms 6ec use t)e concrete c nt f"o- s 1u!ck"y

11.3.3) Oper"tor Error T)e most common error from !ne5per!enced oper tors !s sett!n& up t)e pump!n& system !mproper"y. Oper tors must kno- to set up e c) :o6 so t) t p!pe or )ose on"y needs to 6e remo*ed# not dded on. T)!s !s 6ec use !f t)e p" c!n& cre- ) s to dd )ose once t)e pour !s !n pro&ress# t)e dry cond!t!ons !ns!de t)e dded )ose !s "!ke"y to c use ) nd"!n& of f"e5!6"e ru66er d!sc) r&e )oses c n "so 6e rock : m !s "!ke"y to 6e t)e end resu"t of 6"ock &e. C re"ess pro6"em# s!nce k!nk!n& c n occur. 9

k!nked )ose# s t)e !ns!de )ose d! meter !s reduced#

-)!c) restr !ns t)e &&re& te !n t)e "!ne -)!"e t)e "u6r!c t!n& &rout !s ""o-ed to p ss. Prem ture "oc "!%ed -e r of t)e )ose# nd e*entu " rupture of t)e )ose# m y "so occur t t)e po!nt -)ere t)e )ose !s k!nked.

12.) C*eck#n' for )e"r Pump!n& perform nce s -e"" s s fe oper t!on of t)e pump!n& system m y 6e ffected 6y -orn coup"!n&s or & skets# -)!c) m y "et !r !nto t)e "!ne or ""o- &rout to esc pe. Coup"!n&s typ!c ""y -e r on t)e surf ce t) t comes !nto cont ct -!t) t)e p!peE nd & skets need to 6e c"e ned !f t)ey ) *e concrete rem !n!n& !n t)e c *!ty. T)e & sket s)ou"d 6e rep" ced !f t)e center "!p !s -orn out. C "*es s)ou"d 6e rout!ne"y !nspected for -e r nd proper sett!n&s. T)e most ccur te - y to !nspect for -orn p!pe"!ne !s -!t) & u&e spec!f!c ""y des!&ned to me sure t)e t)!ckness of stee" p!pe. In dd!t!on# t)e p!pe ends must 6e !nspected for -e r# c"e n"!ness nd to m ke sure t)ey re comp t!6"e -!t) ot)er p!pe nd coup"!n&s to 6e used on t)e :o6. 9mer!c n= s!%ed nd 0urope n=s!%ed r !sed ends re not comp t!6"e. Comp t!6!"!ty must "so 6e ensured !f

13

Pumped Concrete

p!pe from d!fferent m nuf cturers re used to&et)er# s!nce p!pe :o!nts c n pose ser!ous ) % rd !f t)e ends nd coup"!n& do not m tc).

13.) Secur#n' t*e System Improper t!e=do-n !s one of t)e most common c uses of cc!dents -)en pump!n& concrete. $upport 6r ckets# des!&ned to )o"d p!pe"!ne !n e!t)er tr nsfer t)e pump!n& tor1ue to 6u!"d!n& co"umn or 6e m. )or!%ont " or *ert!c " pos!t!on# s)ou"d 6e sp ced e*ery 18 to 1. feet !n order to t ke -e!&)t off of t)e coup"!n& :o!nt# nd to

13.1.) C$e"n#n' t*e System If done !mproper"y# c"e n!n& t)e system fter t)e d !"y pump!n& :o6 c n 6e *ery

) % rdous. ( ter s)ou"d 6e used for c"e n!n& -)ene*er poss!6"e nd pr ct!c "# s!nce !t !s t)e 6est nd s fest c"e n!n& met)od * !" 6"e. If c"e n!n& -!t) compressed !r# remem6er t) t t)e pressure 6u!"ds up# nd m y rem !n !n t)e "!ne e*en fter t)e supp"y !s s)ut off# so pressure c n 6e of suff!c!ent force to prope" 6"eed=off * "*e s)ou"d "- ys 6e !nst ""ed on t)e system -)en us!n& compressed !r. Remem6er t) t t)!s c"e n=out 6 "" t)rou&) t)e open end -!t) enou&) force to penetr te concrete 6"ock - "". T)erefore# -)et)er us!n& - ter or !r pressure# !nst "" n end c p nd c tc)er to pre*ent !n:ury to -orkers or d m &e to property.

14