One of milestones after-sales service concrete pump truck is its regular cleaning, which must be carried out daily before starting work and at its completion. Before starting vigorous activity, it is necessary to flush the mechanism with a starting solution, and then treat it with water and compressed air. Flushing the concrete pump truck in this order is necessary to maintain the equipment's suitability for daily and trouble-free operation. The slightest omission can cause failure of important parts and mechanisms of the unit. If your core business is concrete pump rental, the quality of functioning of the copies provided to customers must be impeccable.
Why carry out daily maintenance?
In the event that the mixture is fed without preparation into a dry-coated concrete pipeline, the risk of clogging the supply line and the appearance of plugs from the solution, which can stick to the walls of the container, increases. The starting mixture used for cleaning can be specialized and purchased from specialized companies or homemade. The concrete pump is flushed using the following resources:
- 200 liters of water for several stages of cleaning;
- Air compressor;
- Flushing link capable of operating at an applied pressure not exceeding 10 bar;
- Wads for washing from a sponge of a cylindrical or spherical shape, the size of which will correspond to the diameter of the concrete pipeline.
The concrete pump truck must be cleaned immediately after the final batch has been unloaded from it. concrete mix. At the same time, everything necessary materials for cleaning must be prepared in advance before the container is emptied. The operator at the site where the concrete is being poured must monitor the delivery of the last batch in order to immediately begin the flushing procedure.
Algorithm of the cleaning process of the concrete pump truck
The launch of the starting mixture into the functional volume of the pump must be carried out using a wad and a ball, which are also necessary at the end of the work. Tools made of sponge material are easy to dip into the container and are pre-wetted with starter mix to make the cleaning process more efficient. The uniformity of the distribution of the composition guarantees the washing off of the adhering composition from the walls of the concrete pump. When the flush kit is introduced into the unit, the needle valve pins must be opened and closed when service is complete.
Immediately after such treatment, the container is filled with a solution that is in its volume during the entire shift in order to avoid the appearance of traffic jams from the air. If the operator notices delays and malfunctions, it is necessary to use reverse pumping and direct operation so that the concrete mass does not delaminate and is constantly mixed. In the case when the truck-mounted concrete pump has been at rest for more than thirty minutes, it is necessary to clean it according to the same algorithm as at the beginning or at the end of the shift.
Procedures are carried out within half an hour using up to two cubes hot water, which is sent to the container through a hose resistant to pressure not exceeding 10 MPa. Water heating can be carried out due to the exhaust gases produced by the pump. Quick preparation should be arranged with particular care, especially if the temperature environment constantly fluctuates, low or excessively high, so that it happens in drought or frost.
Concrete pumps are cleaned after the operator's command. Water is poured into the hopper up to the level of the pistons to prevent air from entering the cylinders. At this time, the final part of the solution is supplied to the treated area. Upon completion of the filling, the reverse mode is activated. The pressure is reduced, the remnants of the composition are mixed with water in the hopper, the balls are launched and the container is cleaned by blowing.
The mixture obtained during cleaning is drained, a washing kit is introduced into the concrete pipeline and compressed air is supplied, which creates the necessary conditions for the constant movement of the sponge in the concrete pipeline. Then the procedure is repeated with the use of water and in the final the usual rinsing is carried out, after which the unit is again ready for high-quality functioning.
How to get rid of leftover concrete mix?
Concrete mortar has specific physical and chemical properties, therefore, volumes of material unsuitable for further use must be eliminated, taking care of the place of discharge in advance. When cleaning concrete pumps, you can't just dump the mass on the ground, so you will need special collection boxes or use one of the automixers.
In the first case, suitable containers are needed, the height of which will be at least 2 meters and the depth - half a meter. A kind of formwork is lined with PVC film and all residues washed during cleaning can be easily transported for disposal.
The second option involves the use of a hose and a hopper, into which the remains of the mixture are immersed, followed by starting in the "loading" mode, after which flushing begins.
Cleaning a concrete pump truck is an important procedure that directly affects the quality of the equipment, so you should prepare for it in advance by thinking through all the nuances and preparing the necessary consumables.
I'm going to build a house and buy necessary equipment. Can you please tell me what is the meaning of the instructions for the concrete pump truck?
Expert answer:
The concrete pump truck is a modern mobile special equipment that can supply the finished concrete composition both in vertical and in horizontal position. Strict adherence to the instructions of the concrete pump truck simplifies construction work.
When working as a concrete pump, there is no need to rearrange the distribution booms. Mobile installation does not require additional transport. It does not need to be disassembled and reassembled with each permutation. Manipulations are carried out at a distance of 10 to 65 meters.
Specificity of the concrete pump truck
This is a set of aggregates:
- concrete pump - a device that converts the energy of a hydraulic motor into the energy of the movement of liquid concrete;
- hydraulic drive - a device that uses the energy of a fluid for its work;
- receiving hopper - a container into which the source material is loaded;
- swivel distributing boom - a system designed for fast and convenient delivery of concrete to the site of action;
- hydraulic supports - parts that are rubber-metal vibration isolators.
The ability of the device to work at low temperatures
According to the instructions, the truck-mounted concrete pump is not recommended to be used in conditions low temperatures. The limit is -5 degrees Celsius. But, if there is an urgent need for work, then the machine should be prepared for this. To preparatory activities relate: 
- replacement of oil and grease with low-temperature options;
- oil preheating up to +10 °C;
- insulation and heating of the concrete pipeline.
Pumping the starting mixture, along with flushing the concrete pipeline, is a mandatory operation in the maintenance of complex equipment. Elephant Slick Pro has proven itself well when starting concrete and plaster pumping units. The mixture is available as a water-soluble powder. Its purpose is to lubricate the pump line. The composition prevents clogging of pipes.
concrete mix requirements
The concrete pump instruction states that the concrete composition should contain 30% crushed stone and 40% gravel. The maximum size of crushed stone should not exceed 37 mm. This parameter for gravel is limited to 50 mm. Recommended brands of concrete mix - from M-300 and above. Mobility concrete composition for hydraulic drive - 40–120 mm. Failure to comply with these conditions will lead to problems: a small mobility of the consistency, delamination into separate components.
1. Before stopping the pumping of the concrete mixture, it is necessary to check:
Availability and serviceability of a set of devices for cleaning the concrete pump and
supply of water required for flushing.
2. The set of devices for cleaning the concrete pipeline consists of two sections.
The first section will be made from the water pressure valve, hose and adapter; she must always assembled be kept near the pump.
The second - consists of a branch pipe with two wads. Wads, pre-moistened, are placed in the pipe shortly before the start of washing.
3. The water supply to the mixer hopper must be carried out at a rate that ensures its filling within 5 minutes.
4. Cleaning of the concrete pump and concrete pipeline is carried out in the following order:
a) the supply of concrete mix to the mixer hopper is stopped;
b) all the concrete mixture remaining in the mixer hopper is pumped into the concrete pipeline until the mixer hopper is completely empty;
c) the branch pipe of the concrete conduit connected to the valve box of the pump is disconnected from it;
d) a tray for water drainage is installed under the outlet of the pump;
e) after disconnecting the concrete pipeline from the concrete pump, the latter is thoroughly cleaned of the concrete mixture and washed;
f) after cleaning the pump, it is necessary to knock out the damper from the wedge hole of the stimulator and replace it with a suction water valve, and the valve is installed with a rubber gasket down;
g) two links are disconnected from the concrete conduit and a branch pipe with wads is connected instead of them;
h) the first flushing section (water discharge valve, hose and adapter pipe) is connected to the pump neck with wedges and to the pipe with wads - with a standard lock;
i) the pump is launched on water and must operate at low speed until the concrete mixture begins to flow from the concrete pipeline;
j) water supply to the mixer hopper must be carried out continuously during the entire cleaning of the concrete pipeline.
5. When cleaning the concrete pipeline, it is necessary to monitor the tightness of its butt seals and, in case of water leakage, knock out the wedges.
6. The tightness of the joints that let water through must be restored immediately after cleaning.
7. The duration of cleaning the concrete pump and concrete pipeline should not exceed 40 - 50 minutes.
Delayed cleaning may cause the concrete mix in the pipes to set.
8. When cleaning the concrete pipeline, it is necessary to monitor the speed of movement of the wads through the pipes, determining the position of the wads by the sound when the concrete pipeline is tapped. The speed of the wad should correspond to the speed of a slowly walking person.
9. When cleaning the concrete pipeline, it is necessary to monitor the readings of the ammeter. In the case of large readings of the ammeter and the cessation of the exit of the concrete mixture from the concrete pipeline, it is necessary to stop the pump and eliminate the blockage that has occurred.
10. In case of blockage of the concrete pipeline during cleaning, which is usually the result of water penetration into the concrete mix, it is necessary to disconnect the concrete pipeline in front of the wad and clean the link from the concrete mixture, put the wad into the released link, connect the concrete pipeline and continue cleaning.
To clean the system from concrete residues, you will need:
1) warm water(200 l for several cleaning cycles);
2) air compressor;
3) a flushing link designed to supply water or compressed air(under pressure not more than 10 bar);
4) flushing balls and wads in the form of a cylinder, which are made of spongy material to fit the diameter of the concrete pipeline.
Cleaning of the concrete pipeline should be carried out immediately after the completion of the delivery of the last batch of concrete, having prepared everything necessary for this before emptying the last automixer. It is important to keep in constant communication with the operator at the concreting site - he must inform when only the volume of mixture contained in the system on the floor remains to be poured. this moment. After such a signal, it is necessary to stop the supply of concrete and pour water into the concrete pump hopper - the resulting liquid mixture is maintained in the hopper at the lowest possible level, but not so much that air enters the piston cylinders (air entry will lead to a problem - it will stratify the mixture). Having completed the pouring, the operator of the concreting site gives a signal to the operator of the concrete pump - he switches the operation of the concrete pump to reverse (reverse mode) to reduce the amount of mixture in that part of the concrete pipeline that is located closer to the work site and to reduce the pressure in the concrete pipeline. Then the conduit is disconnected from the pump and extended with additional sections to reach the area intended for the discharge of the contents of the concrete conduit (they must be prepared and assembled to the desired length in advance). Be sure to put on the end pipe that leads the concrete pipeline to the discharge site, the nozzle-catcher of the flushing ball - it can fly out at a decent speed. The operator of the concreting site removes the distributing hose from his end of the concrete conduit and installs a blowing nozzle instead of the last elbow, after inserting a flushing ball into the concrete conduit with plenty of water moistened (it is better to combine - first insert the ball, followed by the wad). The start of compressed air by the operator of the concreting site and the transfer of the needle valve fingers to the “open” position must be performed as synchronously as possible - the movement of the flushing ball along the concrete conduit should not stop even for a minute. It is better to carry out the flushing operation twice - it is necessary to re-supply water to the concrete pipeline through the concrete pump by switching the needle valve to the “closed” position. The hopper of the concrete pump is washed and cleaned with a stand under the outlet of the drain tray. It is especially convenient if this model is equipped with its own water pump with a hose and a container for water heated by hot gases from the exhaust pipe - it is easier to flush and remove the remains of the concrete mixture, because. no need to think about where to get hot water.
Dumping of concrete residues
Where to dump the remains of concrete after flushing the system? You can’t just dump it on the ground - this will seriously damage the soil, because the semi-liquid material will spill over the construction site. There are two options:
1) collection of washing residues in a box;
2) dumping the penultimate automixer into the bunker, having previously coordinated this operation with the concrete supplier.
In the first option, you need to assemble a square formwork box from boards (height 2,000 mm, depth 500 mm), lining it with PVC film 200 microns thick - after washing, its contents can be moved for disposal. The second option: run the discharge hose from the concrete pipeline into the automixer hopper, run it in the “loading” direction and secure it with a chain (otherwise it will jump out and splatter everything), then start the flushing process described above.
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