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Analysis of Key Technical Points in Long-Distance Pumping for Fully Automatic Wet-Spray Trolleys
Release time:
2026-07-14
Source:
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Summary:
Long-distance pumping is the core application scenario for fully automated wet‑spraying rigs in large tunnels, underground projects, and the support of steep, high‑slope faces. The technical challenges lie in mitigating pressure drop, loss of workability, and the risk of segregation during extended conveyance. Below, we systematically outline the technical approach to long-distance pumping from four perspectives: equipment selection, process optimization, pipeline layout, and intelligent control.
I. Equipment Selection and Performance Matching
1. Pumping System Upgrade
For long-distance pumping, a high-pressure, high-displacement hydraulic pumping system should be selected, with its key parameters meeting the following requirements:
Outlet pressure: ≥16MPa (For general engineering, it is 8-12MPa ), in order to overcome the frictional resistance of long pipelines;
Theoretical Displacement: ≥40m³/h , ensuring conveying efficiency;
Hydraulic system power: ≥150kW , providing continuous power support.
For example, a certain brand’s wet-spray carriage employs a tandem hydraulic pump with two cylinders, increasing the piston stroke to… 1200mm , increased single-pump delivery volume 25% , effectively reducing the number of commutations and lowering energy losses.
2. Optimization of Conveying Pipe Diameter
Pipe diameter selection must balance flow rate and pressure loss:
Horizontal conveying distance ≤300m At that time, prioritize the use of φ125mm Pipe;
Distance > 300m or vertical lifting height > 50m At that time, adopt φ150mm Pipe, reduce the flow velocity (recommended to be controlled at 1.5-2.0m/s ), reducing wear and segregation.
Practical experience from a certain cross-sea tunnel project indicates that, φ150mm Pipe in 500m At a distance, the pressure loss is relatively… φ125mm Manage reduction 40%。
II. Dynamic Control of Process Parameters
1. Mix Proportion Adaptability Design
Long-distance concrete pumping requires high fluidity and low viscosity:
Water-cement ratio: kept at 0.40-0.45 , mixed in 15%-20% Fly ash or silica fume improves workability;
Admixture: added 0.8%-1.2% Polycarboxylate superplasticizer, initial slump ≥220mm , degree of expansion ≥550mm；
Aggregate gradation: Adopted 5-20mm Continuous grading, maximum particle size ≤25mm , reducing the risk of pipe blockages.
In a certain high-speed railway tunnel project, by optimizing the mix proportions, the concrete was able to… 800m Remains intact after delivery 180mm Slump meets construction requirements.
2. Pump speed staged control
During the startup phase, a low speed is used ( 6-8 m³/h ) Pumping 2-3 minutes; once the pipeline is fully filled with concrete, gradually increase the speed to the design value ( 25-35 m³/h ). In one project, a staged speed-up strategy was employed to reduce the surge pressure at pipeline startup. 35% , reducing the likelihood of aggregate breakage and pipe blockages.
III. Pipeline Layout and Drag-Reduction Design
1. Pipeline Layout Principles
Straight-line priority: reduce the number of bends and bend radii. ≥3 Double the pipe diameter (for standard projects, it is… 1.5 times);
Slope control: for horizontal pipes, every 100m Settings 1 A vertical bent pipe, each vertical pipe… 5m Settings 1 A horizontal buffer section to prevent segregation of the concrete due to self‑flow;
Fixed support: every 3-5m Install pipe clamps to prevent pipe vibrations from loosening the joints.
In a certain hydropower station project, by optimizing the pipeline layout, it was possible to… 800m The number of pipe blockages per day for the conveying distance has decreased from… 5 Subsequently reduced to 1 Next.
2. Application of Drag-Reduction Technology
Inner-wall polishing: Stainless steel tubes subjected to polishing treatment have a reduced coefficient of friction to 0.08 (Ordinary steel pipes are 0.15 );
Lubrication layer formation: Prior to pumping, the pipeline is lubricated with cement slurry to form 0.5-1mm Lubrication layer, reducing frictional resistance 20%-30% ；
Pulsed vibration device: Vibrators are installed at critical points in the pipeline to disrupt the internal arching effect of concrete through pulsed vibrations, thereby reducing blockages.
IV. Intelligent Monitoring and Emergency Support
1. Real-time pressure monitoring
Pressure sensors are installed at the pump outlet, along the pipeline, and at the terminal end; when the pressure suddenly increases… 15% At that time, the system automatically reduces the displacement. 20% and activates the pulse‑vibration function. A certain model of wet‑spraying boom truck, leveraging this technology, advances the pipe‑clogging early‑warning time to before the blockage actually occurs. 30 Seconds.
2. Emergency Response Plan
High-pressure air back-blowing: Equipped with 10MPa Compressed air tank; reverse blow to clear blocked pipes. 8 Can be removed within minutes. 85% Obstruction;
Quick‑connect fittings: Utilize clamp‑type quick couplings, with a single pipe section removable in… ≤2 Minutes, reducing repair time;
Backup pumping system: Equipped with dual pumping units; in the event of a main pump failure, 30 Automatically switches to the standby pump within seconds, ensuring uninterrupted construction.
The fully automatic wet-spraying carriage has successfully achieved, through equipment upgrades, process optimization, pipeline drag reduction, and intelligent monitoring, 1000m Long-distance pumping at the advanced level. Following the application of this technology in a certain subway tunnel project, the daily shotcrete output exceeded 200 m³ , with the rebound rate controlled at 12% Within, efficiency is improved compared to traditional processes. 50% , providing reliable technical support for the efficient construction of large-scale underground projects.
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