TRAINING PRESENTATION Concrete Boom Pump pipeline Checking Procedure

Problem Statement / Root Cause / Preventive Action

TARGET EQUIPMENT'S:

• Concrete Boom Pump

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Problem Statement
Incidents associated with the failure of Boom pump concrete delivery pipelines have occurred in worksites due to
not following technical Specifications and standards recommended by OEM :
1. The failure of steel pipelines due to excessive wear or 3, Inspection caps on T pieces' or elbows around the
the use of pipe that does not have adequate pressure hopper area of the pump blown off due to pipe clamp
rating for the pressure applied by the concrete pump. failure.
Concrete Pump 4th boom pipeline failure

2, Pipe clamps failing under pressure causing the pipeline to

fail at the joint between the two pipes, resulting in concrete
being sprayed at high pressure.
4, Rubber delivery hoses dropping off
the end of concrete placement booms
due to inadequate securing, that is,
failure of clamps and safety chains
not fitted properly.
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Problem Statement
Concrete blown out due to pipeline’s damage, which were used beyond its limits. when pipeline wall thickness was
checked it was found .5 mm instead of 2.7 mmm which is the maximum limit for 4 mm pipeline.

.5 mm Thickness

.5 mm Thickness

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Root Cause
MAIN WEAR ZONES
The Amount of wear on concrete delivery components strongly depends on the operating conditions (Concrete type,
Concrete pump stroke rate , etc.) We therefore recommend testing new components after having pumped a specified
amount of concrete. Then according to the wear and tear- plan further dates:
Delivery Tubes
The main wear zone is located in the direction of concrete flow approx. 100 mm behind the
flange (Fig.: 1).

Pipe elbows
The main wear zone is located in the direction of concrete flow in the "inlet bend" (Fig.: 2).

Two-layer materials
Two-layer materials must be exchanged at the latest when the inner hardened layer has worn
away in places up to the outer layer (Fig.: 3).

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Root Cause
4mm PIPE AVAILABLE WITH US IN GHALA – quickly worns out based on higher grades of concrete.

4 mm

Single Wall – Thickness 4 mm

Branded

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Root Cause
7mm PIPE Available with us in Ghala – Not Original.

7 mm

Thickness ?

Thickness 7 mm

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PREVENTIVE ACTION
Below is the Best example of Twin wall pipe and is highly recommended.

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PREVENTIVE ACTION Specific guidance relating to the safety of concrete delivery pipelines includes :
Recommended Control Measures
Pipeline and Reducer
• The working pressure of the pipe and reducer must exceed the maximum pressure applied by the pump. Factors of
safety for the concrete delivery pipeline.
• Concrete delivery pipe, including the reducer should be identifiable through a unique identification code that
corresponds to documented records on the concrete pump.
• It is preferable that the pipe is also marked with a manufacturer's name (or trademark) and a pressure rating.
• Documented information on the correct pipe specification, determined by the concrete pump manufacturer, must
be kept with the concrete pump.
• Pipe should be removed from the pump and discarded before it reaches its minimum thickness allowance as
specified by the concrete pump manufacturer for the grade and type of pipe being used.
• In the case of single wall pipe, actual thickness readings are to be taken and recorded in a log book at intervals not
exceeding one month (i.e. using a calibrated ultrasonic thickness tester).
• Thickness of twin wall pipe cannot be easily checked unless pipe clamps are removed and an internal inspection is
made. Wear rates on twin wall pipe will generally be less than single wall pipe however a documented system to
reduce the risk of pipeline failure should be implemented for any pipe.
• In the case of twin wall pipe, internal inspections should also be carried out to verify if the pipe is wearing at the
predicted rate. The discard procedure should not be based solely on assuming that the pipe can safely withstand a
specific volume of concrete prior to being removed and discarded.
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PREVENTIVE ACTION
Pipe line and elbow location in a Concrete pump
13 • First After 5000 cubic meter of pumping concrete, please check the desired pipelines for wear.
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14 • Further checking of the pipelines need to be planned accordingly.
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• Wear will be less or more dependent on the grade of concrete, flow of concrete and pressure.
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16 • 3rd, 4th and 5th boom pipeline’s have more wear rate, compared to 1st and 2nd boom pipelines.
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9
10
8 18

7 19
6
20
5
22
4 21 23
24
3
25 26 27 28
2
29
1

31

30

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Preventive Action
Pipe Clamps
• Pipe clamps should be permanently marked with the
manufacturer's name (or trademark) and the
maximum permissible operating pressure in Bar or
Pressure Nominal (PN).
• Photographs 3 and 4 display clamps that are
appropriately marked.
• The clamps must be rated at a higher working
pressure than the maximum working pressure of the
Photograph 3: An example of acceptable marking on pipe clamps.
concrete pump.
• Pipe clamps that have worn pins, cracks,
deformations or any other signs of excessive wear
must not be used.
• The pipe clamps should be inspected for wear and
damage before each use.
• Quick release clamps must be fitted with locking pins
to ensure inadvertent release does not occur.

Photograph 4: An example of acceptable marking on pipe clamps.

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Preventive Action
Pipe Clamp Coupling –OEM Models

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Preventive Action
CONCRETE PUMP TWIN WALL ELBOW from OEM is Recommended

• Twin wall elbows provide long life.

• Pressure rating & certification is mandatory.

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PREVENTIVE ACTION
Pipe line cleaning is essential before inspection

Reverse Pumping & cleaning the pipelines

Movement Cement / Concrete left

Running Resistance
Sponge Cement / Concrete left Suction

• After cleaning the pipelines

by ball passing and flushing,
carry out the inspection of
pipeline and elbow wall
thickness as per the
procedures specified in the
up coming presentations.
out

in
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PREVENTIVE ACTION
WALL THICKNESS MEASUREMENT*
The wall thickness of delivery tubes can be measured using a commercial wall-thickness sensor (e.g.
Fig.: 7 – Kroeplin GmbH).
Note: Double-walled delivery tubes cannot be measured using ultrasound.
Procedure:
1. Type specification of the pipeline component : Determine which type
of which quality is available. Depending on the type, the respective
measurement sheet is selected. Should you have questions or be
missing measurement sheets, please contact SCHWING customer
service.
2. Specification of the installation situation : The respective installation
situation is specified on the measurement sheet, according to the
installation present.
3. Taking the measurement : Depending on the prescribed measurement
methods, the respective minimum wall strengths must be specified.
4. Comparison of indicator values : The measured minimum wall
strengths must now be compared with the indicator values taken from
the relevant measurement sheets.
5. Decision on further use : If one of the measured values has been
reached, then at this critical point the delivery tube has a remaining
wall strength of 0.5 mm and must be replaced as soon as possible.
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PREVENTIVE ACTION
1. TUBE TYPE TUBES
1.1 Installation situation 1 - Tube after tube
Measuring points:
(P1) Approx. 20-30mm behind the welding seam of the inlet flange
(P2) Measurement on the shoulder of the inlet flange around the entire
circumference.
Set the measuring tip as far on the end of the shoulder as possible, in
the direction of the groove. Measurement sheet tubes
1.2 Installation situation 2 - Tube after elbow (As of 31.10.2012, excerpt from the Esser Sales Booklet EM120029 _ EM130023 DE 141208) :
Measuring points:
(P1) Approx. 20-30 mm behind the welding seam of the inlet flange in extension of the
elbow inner radius and elbow outer radius.
(P2) Measurement on the shoulder of the inlet flange around the entire circumference.
Set the measuring tip as far on the end of the shoulder as possible, in the direction of
the groove.

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PREVENTIVE ACTION
2. TUBE TYPE - ELBOWS

2.1 Installation situation 1, 2, 3 - Elbow after elbow/tube/tapered tube

For all elbows of 10° to 90° with standard

connection, but without leg extension

Measurement points:

(P1) Measurement on the shoulder of the

installation flange around the entire
circumference.
Set the measuring tip as far on the end of the
shoulder as possible, in the direction of the MEASUREMENT SHEET ELBOWS:
groove. (As of 31.10.2012, excerpt from the Esser Sales Booklet ES4045):

(P2) Measurement on the shoulder of the outlet

flange in extension of the elbow outer radius.
Set the measuring tip as far on the end of the
shoulder as possible, in the direction of the
groove.

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PREVENTIVE ACTION
3. TUBE TYPE TAPERED TUBE

Measurement points:

(P1) Measurement in the 50 mm area in front of

the outlet flange welding seam.

(P2) Measurement on the shoulder of the outlet

flange around the entire circumference.

Set the measuring tip as far on the end of the

shoulder as possible, in the direction of the groove.

MEASUREMENT SHEET TAPERED TUBE:

(As of 31.10.2012, excerpt from the Esser Sales Booklet ES4045):

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PREVENTIVE ACTION
4. MEASURING THE WALL THICKNESS OF TWO–LAYER PIPES

• Visual inspection for cracks. Replace in case of

crack formation.
• Measure the wall thickness at the measuring
points P1 and P 2.

Replace if the wall thickness has fallen below the

minimum required (see table).

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 Thank You

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