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Analysis of Key Technical Points in Fully Automatic Wet-Spraying Boom Pumping of Corrosive Concrete
Release time:
2026-07-13
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Summary:
Corrosive concrete, containing chemical constituents such as chlorides and sulfates, poses significant challenges to the durability of equipment, pipelines, pumping systems, and structural integrity. An automated wet‑spraying carriage, through material compatibility, equipment modifications, process optimization, and protective measures, can achieve efficient pumping of corrosive concrete. The following sections systematically outline the technical implementation approach from four perspectives: material properties, equipment protection, process control, and safety maintenance.
I. Characteristics of Corrosive Concrete Materials and Challenges in Pumping
Corrosive concrete typically incorporates sulfate-resistant cement, corrosion inhibitors, or corrosion‑resistant admixtures; its properties, however, increase the difficulty of pumping:
Chemical corrosion risk: Chloride and sulfate ions can corrode metal pipelines, reducing equipment lifespan.
Rapid loss of workability: The admixture accelerates the hydration reaction of cement, resulting in a faster rate of slump loss compared to ordinary concrete. 40%-60% ；
Significant viscosity fluctuations: As the dosage of corrosion‑resistant cementitious materials increases, the range of slurry viscosity variation widens, necessitating dynamic adjustments to pumping pressure.
II. Equipment Protection and Adaptation Modifications
1. Pipeline System Upgrade
Conveyor pipes lined with ceramic or epoxy coatings exhibit improved corrosion resistance compared to conventional steel pipes. 3-5 times. For example, after a certain project adopted ceramic-lined pipes, the service life of the pipeline increased from 200 m³ Extend to 1000 m³ The above. At the bent pipe section, a double… is used. 45° Combined design reduces aggregate impact and lowers the wear rate.
2. Pumping System Optimization
A twin‑cylinder hydraulic pumping system is employed, equipped with wear‑resistant alloy cylinder liners and piston rings, to handle the conveyance of high‑viscosity slurry. A certain brand’s wet‑spraying rig achieves this by increasing the diameter of the concrete cylinder to… 200mm , in coordination with 150kW High-pressure motor, achieving a breakthrough in the vertical conveying height of corrosive concrete. 60 Meter.
3. Intelligent addition of accelerating agent
A corrosion-resistant rapid-setting agent metering pump is configured, with computer‑based automatic control that adjusts the dosage in real time according to the concrete flow rate. For example, at one project, this system has kept the rapid-setting agent dosage error within… ±1% Within this range, ensure effective bonding between the shotcrete layer and the surrounding rock.
III. Precise Control of Process Parameters
1. Mix Proportion Design Optimization
Adopt “ Low water-cement ratio + High-efficiency water reducer + Mineral admixture ” Scheme: The water-to-cement ratio is controlled at 0.35-0.40 , mixed in 15%-20% fly ash or silica fume, and add 0.5%-1.0% A polycarboxylate superplasticizer. Practical application in a certain cross-sea bridge project has demonstrated that this mix proportion can achieve an initial slump of up to 200mm，1 Remains after hours 160mm The above meets the requirements for long-distance pumping.
2. Graded control of pumping speed
During the startup phase, a low speed is used ( 6-8 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. 35% , reducing the risk of aggregate crushing.
3. Temperature and Humidity Management
In high-temperature environments (> 30℃ ) Under such conditions, cold-water mixing or the addition of a retarder is employed to slow down slump loss; in humid environments (relative humidity > 85% ) In this case, the exposure time of the pipeline is shortened to prevent water penetration that could lead to segregation.
IV. Security Maintenance and Emergency Measures
1. Process Quality Monitoring
Install ultrasonic sensors inside the hopper, 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… 2 Reduce 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. Statistical data from a certain project indicate that this cleaning method can extend the service life of the pipeline to 800 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. Testing on a certain project has shown that this device can… 8 Remove within minutes 85% The blockage, restoring construction efficiency.
The fully automatic wet-spraying carriage has successfully overcome the technical bottleneck of pumping corrosive concrete through equipment protection, process optimization, and intelligent control. Following its application in a certain subway tunnel project, the daily spraying volume exceeded 150 m³ , with the rebound rate controlled at 15% Within, efficiency is improved compared to traditional processes. 40% , providing reliable technical support for shoring works in corrosive environments.
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