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Analysis of Key Technical Points in Fully Automatic Wet-Spraying Boom Pumping Technology for Lightweight Concrete
Release time:
2026-07-09
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Summary:
Lightweight concrete, owing to its low density and excellent thermal insulation properties, is widely employed in tunnel primary support, slope stabilization, and other engineering applications. For fully automated wet‑spraying boom pumps to deliver lightweight concrete, it is necessary to overcome technical challenges such as controlling material flowability, optimizing pump pressure matching, and adapting the equipment to meet specific requirements. The following section systematically outlines the technical implementation pathway from four perspectives: material characteristics, equipment modification, process control, and quality assurance.
I. Properties of Lightweight Concrete Materials and Challenges in Pumping
Lightweight concrete typically uses expanded clay, expanded perlite, or foaming agents as lightweight aggregates, and its density is only a fraction of that of ordinary concrete. 30%-50% , but the following pumping challenges exist:
Rapid loss of workability: Lightweight aggregates have a high water absorption, which can easily lead to concrete segregation, resulting in a faster rate of slump loss compared to ordinary concrete. 2-3 times;
High pipeline resistance: The lightweight aggregate has a rough surface, increasing the friction coefficient with the pipe wall. 30%-50% , requiring higher pumping pressure;
Prone to pipe blockage: Lightweight aggregates have low strength and are easily crushed at bends, leading to aggregate buildup and a higher likelihood of clogging compared with ordinary concrete. 40%。
II. Equipment Adaptation and Selection
1. Pumping System Upgrade
A twin‑cylinder hydraulic pumping system is selected, with a delivery pressure that can reach 16MPa , an improvement over the single-cylinder system 60% For example, a certain brand’s wet-spraying carriage has increased the diameter of its concrete cylinder to… 200mm , in coordination with 132kW High-pressure motor, enabling a breakthrough in the vertical conveying height of lightweight concrete. 80 Meter.
2. Pipeline Optimization
Stainless steel pipes with an internally polished surface reduce the coefficient of friction to 0.08 (Ordinary steel pipes are 0.15 ), and reduce the bend radius to 1.5 Double the pipe diameter (standard is 3 times), reducing aggregate crushing. In a certain engineering case, by implementing… 90° The bent pipe is changed to a double one. 45° Combined bent pipes reduce the number of pipe blockages. 70%。
3. Smart Control System Configuration
Equipped with pressure - A dual-loop flow control system that continuously monitors pumping pressure and displacement. When the pressure suddenly increases… 15% At that time, the system automatically reduces the displacement. 20% and activates the pulse vibration function to prevent pipe blockage. A certain model of wet‑spraying truck, equipped with this system, has increased the pumping efficiency of lightweight concrete to 45 m³/h , approaching the level of ordinary concrete.
III. Precise Control of Process Parameters
1. Mix Proportion Design Optimization
Adopt “ Low cement content + High-efficiency water reducer + Fiber-reinforced ” Plan: Cement dosage shall be controlled at 300 kg/m³ Within, incorporate 0.8%-1.2% polypropylene fibers, and added 0.3%-0.5% An air-entraining agent is used to form a lubricating layer of tiny air bubbles. Field trials in a tunnel project have demonstrated that this mix design can extend the slump retention time of lightweight concrete to 90 Minutes, meeting the demands of long-distance pumping.
2. Graded control of pumping speed
During the startup phase, a low speed is used ( 5-8 m³/h ) Pumping 2-3 After a few minutes, once the pipeline is fully filled with concrete, gradually increase the speed to the design value. In one project, a segmented acceleration strategy was employed to reduce the start-up impact pressure in the pipeline. 40% , reducing the risk of aggregate crushing.
3. Dynamic addition of accelerating agent
Adjust the dosage of the accelerating agent in real time based on ambient temperature and conveying distance: for every 1°C increase in temperature, 10℃ , reduced dosage 0.2% ; For every additional increase in conveying distance 50 Rice, with increased dosage 0.3% . After this technology was adopted in a certain cross-sea bridge project, the setting time error of the lightweight concrete was controlled within ±2 Within minutes, ensure effective bonding between the shotcrete layer and the surrounding rock.
IV. Quality Assurance and Emergency Measures
1. Process Quality Monitoring
Install ultrasonic sensors in the hopper of the wet-spraying carriage, each… 5 The concrete’s air content and slump are measured every minute, with automatic alarms triggered in case of abnormal readings. At one project, this device enabled early detection of… 3 Minimize the risk of segregation and prevent pipe blockages.
2. Pipeline Cleaning and Maintenance
Used after each assignment “ High-pressure water flushing + Sponge ball propulsion ” Dual-mode cleaning: first use 20MPa High-pressure water is used to flush away residual concrete from the pipe walls, followed by pushing in a device with a diameter larger than that of the pipe. 5mm sponge balls, thoroughly removing fragmented aggregates. According to statistics from a certain project, this cleaning method can extend the service life of the pipeline to 1500 m³ That’s all.
3. Emergency Pipeline Blockage Response Plan
Equipped with a high-pressure air back‑blowing device, when pipe blockage occurs, the concrete inside the pipeline can be blown out in the reverse direction using compressed air while the pumping system is shut down. Test results from a certain project indicate that this device can… 10 Remove within minutes 90% The blockage, restoring construction efficiency.
The fully automatic wet-spraying carriage has successfully overcome the technical bottleneck in pumping lightweight concrete through equipment upgrades, process optimization, and intelligent control. Following its application in a subway tunnel project, the daily spraying volume exceeded 200 m³ , with the rebound rate controlled at 10% Within, efficiency is improved compared to traditional processes. 50% , thereby providing reliable technical support for the large-scale application of lightweight concrete in shoring works.
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