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The Corrosive Impact of Concrete Residues on Wet Spray Machine Systems
Release time:
2025-10-27
Source:
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Summary:
If a wet spray machine is not cleaned promptly after concrete spraying operations, the residual concrete will gradually harden inside the equipment—such as in delivery pipes, nozzles, and hydraulic systems—and may even cause corrosion, ultimately shortening the equipment's lifespan and reducing construction efficiency. This article analyzes the corrosion mechanisms of concrete residues and proposes effective protection and maintenance measures to minimize equipment wear and repair costs.
I. Corrosion Mechanism of Concrete Residues
1 Chemical Corrosion
Alkaline Erosion: Freshly mixed concrete has a pH as high as 12–13, and the alkaline substances within, such as Ca(OH)₂, can react with metal surfaces, compromising the protective oxide layer and accelerating steel corrosion.
Chloride ion corrosion: If concrete contains chloride salts (such as sea sand or antifreeze agents), Cl⁻ can penetrate the metal passivation film, leading to pitting corrosion and stress corrosion cracking.
2 Physical Wear and Deposition
Consolidated wear: After the remaining concrete hardens, it forms an abrasive material that accelerates the wear of mechanical components such as pistons and delivery cylinders.
Pipe blockage: Partially hardened concrete adheres to the pipe walls, reducing the flow diameter and increasing pumping resistance, which leads to equipment overload.
3 Electrochemical Corrosion
In humid environments, concrete residues form a galvanic cell with metal components, where the highly alkaline areas act as the cathode and the low-pH regions serve as the anode, accelerating localized corrosion.
II. Major Affected Areas and Symptoms
| Affected Component | Corrosion Appearance | Consequences |
| Transmission Pipes and Nozzles | Internal Wall Rusting, Scaling, and Thickening | Flow Rate Decreases, Spray Pressure Becomes Unstable |
| Hydraulic System Seals | Rubber Aging, Metal Fittings Rusting | Hydraulic Oil Leaks, Reduced System Efficiency |
| Mixing device bearing | Grease contamination, rolling element seized | Increased rotational resistance, motor overload |
| Boom Structure Steel Components | Surface Rust Spots, Stress Corrosion at Welds | Reduced Structural Strength, Safety Hazards |
III. Protective and Maintenance Measures
1 Clean up promptly after construction
High-pressure water flushing: Immediately after the operation, use a high-pressure water gun at 10–15 MPa to flush the pipes and nozzles, preventing concrete from setting.
Chemical cleaners: Use mild acids (such as oxalic acid) or specialized cleaning agents to dissolve stubborn residues, but be sure to avoid corroding metals.
2 Material Optimization
Anti-corrosion coating: Spray an epoxy or polyurethane coating onto the inner wall of the transmission pipeline to isolate it from direct contact with concrete.
Wear-resistant alloys: Key wear components (such as nozzles and pistons) are made from high-chromium cast iron or tungsten carbide materials.
3 Daily Maintenance
Daily Inspection: Focus on checking the sealing and lubrication conditions to prevent concrete from entering the bearings or hydraulic system.
Weekly maintenance: Remove parts prone to buildup (such as filters) for thorough cleaning.
4 Environmental Control
Humidity Management: Keep the equipment dry during prolonged periods of inactivity, and apply rust-preventive oil to metal surfaces when necessary.
Chloride Ion Monitoring: Avoid using concrete materials containing chloride salts.
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