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Technical Requirements for High-Grade Concrete Pumping Using Wet Spray Vehicles
Release time:
2026-02-17
Source:
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Summary:
High-grade concrete—typically referring to concrete with a strength grade of C50 or higher—poses significant challenges during pumping due to its high cementitious material content, low water-to-cement ratio, and high viscosity. To ensure smooth pumping of high-grade concrete using wet-mix shotcrete machines, targeted measures must be taken from multiple aspects, including material mix design, equipment adjustments, and process control.
I. Key Technical Parameters of Concrete Mix Proportions
Optimization of Cementitious Material Systems
The total amount of cementitious materials in high-grade concrete typically exceeds 450 kg/m³. Special attention should be paid to the following: The cement dosage must be kept within a reasonable range to avoid excessive amounts that could increase viscosity; high-quality fly ash or mineral powder should be incorporated to improve the rheological properties of the slurry; the silica fume content should not exceed 8% to prevent a significant reduction in workability; and the compatibility among different cementitious materials must be verified through testing.
Aggregate Selection and Gradation
The characteristics of aggregates directly affect pumping resistance: the maximum size of coarse aggregates should not exceed 20 mm; continuous grading should be adopted to reduce the void ratio; the content of flaky and elongated particles should be kept within 10%; and the fineness modulus of fine aggregates should ideally fall within the range of 2.6 to 2.9.
Admixture Selection
High-efficiency water reducers are a key technological measure: Poly-carboxylate-based high-performance water reducers should be selected; the water-reducing rate must reach 25% or higher; they must exhibit excellent slump retention performance; and they must be highly compatible with cementitious materials.
II. Equipment Adjustment and Modification Requirements
Hydraulic System Parameter Settings
Adjustments tailored to the characteristics of high-viscosity concrete: Increase the system’s working pressure by 10%-15%; correspondingly raise the setpoint of the relief valve; and appropriately reduce the pumping speed to enhance the system’s cooling capacity.
Pump mechanism improvement
Key components need to be reinforced: the hardness of the inner wall of the delivery cylinder must be increased; the diameter of the S-valve should be appropriately enlarged; the wear resistance of the wear plate must be enhanced; and the reliability of the sealing system must be improved.
Pipeline System Optimization
Special attention must be paid to pipeline configuration: The main pipeline diameter shall be no less than 125 mm; use ultra-wear-resistant pipeline materials; minimize the number of elbows and reduce their bending angles; and increase the density of pipeline support points.
III. Key Control Points for Pumping Operations
Preparation before pumping
Thorough preparation is crucial: Increase the amount of lubricating mortar to 0.8–1.0 m³; ensure that the mortar consistency matches that of the concrete; extend the no-load running time of the equipment to 15 minutes; and conduct a comprehensive inspection of the system’s sealing performance.
Pump Process Control
Fine-grained process management: Initially, the pumping rate should be controlled at 8–12 m³/h; gradually increase it to the normal operating speed; maintain continuous pumping to avoid interruptions; and closely monitor changes in system pressure.
Special Case Handling
Measures for handling abnormal conditions: Immediately reverse the pump when pressure rises abnormally; for short-term interruptions, run the pump in reverse periodically; adjust the mix proportion immediately upon detecting segregation; and follow standard procedures when pipe blockage occurs.
IV. Quality Control and Monitoring
Work Performance Testing
Strictly monitor the concrete’s condition: The slump at the factory shall be controlled within 200 ± 20 mm; the spread shall be no less than 500 mm; the time for discharging from the truck shall not exceed 15 seconds; and the slump loss after 2 hours shall not exceed 30 mm.
Equipment Parameter Monitoring
Real-time monitoring of equipment operating status: System pressure fluctuation range ±2 MPa; oil temperature controlled within the 30-60℃ range; monitoring of pump delivery rate stability; temperature checks at critical components.
Construction Quality Verification
Jetting effect inspection: The rebound rate shall be controlled within 15%; the smoothness of the jetted surface must meet the requirements; compactness shall be verified by tapping; and samples shall be taken promptly for strength testing.
V. Safety Precautions
Equipment safety
Ensure equipment operational safety: Regularly inspect the fatigue condition of structural components; monitor the sealing performance of the hydraulic system; prevent the system from operating under excessive pressure; and install multiple safety protection devices.
Operational safety
Standard Operating Procedures: Strictly adhere to operating procedures; wear necessary protective equipment; keep the work area clean and tidy; and set up safety warning signs.
Emergency Handling
Develop an emergency response plan: Clearly define procedures for handling pipe blockages; prepare emergency repair equipment; establish a rapid-response mechanism; and regularly organize emergency drills.
VI. Special Requirements for Maintenance and Care
Daily maintenance
Strengthen daily maintenance efforts: Inspect the condition of vulnerable parts every shift; promptly replace worn components; maintain system cleanliness; and record equipment operating data.
Regular maintenance
Shorten the maintenance cycle: Conduct a comprehensive inspection of the pumping system monthly; replace wear-resistant components quarterly; perform semi-annual maintenance on the hydraulic system; and carry out annual equipment performance assessments.
Preventive maintenance
Establish an early warning mechanism: Predict maintenance based on operational data; proactively stock critical spare parts; conduct regular performance inspections; and establish equipment health records.
Conclusion
High-grade concrete pumping places higher demands on the performance of wet-spraying rig equipment and construction techniques. By optimizing mix design, adjusting equipment parameters, refining process controls, and strengthening maintenance and upkeep, we can effectively address the challenges associated with pumping. It is recommended that construction units conduct thorough process trials before commencing projects to gain a comprehensive understanding of the pumping characteristics of specific materials and develop detailed operation guidelines. At the same time, it is crucial to enhance collaboration with technical support organizations, continuously accumulate experience, improve technical capabilities, and ensure both the quality and efficiency of high-grade concrete spraying operations.
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