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Fully Automatic Wet-Spraying Trolley with Vertical Pipe Support System
Release time:
2026-08-28
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Summary:
In concrete spraying operations, fully automated wet‑spraying rigs typically need to pump concrete to considerable heights to perform shotcrete support on high‑elevation surfaces such as tunnel arches and sidewalls. The vertical delivery pipeline is subjected to substantial downward pressure from the concrete’s own weight, as well as pulsating forces generated by pumping surges. If the support is inadequate, this can result in loose pipe joints and grout leakage, or unstable spraying pressures; in more severe cases, it may lead to bent‑pipe fractures or pipe disconnection—both of which pose significant safety risks. Establishing a reliable vertical pipeline support system is an essential prerequisite for ensuring the safe operation of wet‑spraying rigs during high‑altitude pumping.
I. Main Components of the Vertical Pipe Support System
The support system for the vertical pipeline of the wet-spraying carriage consists of three components: “bracket fixation, backflow prevention measures, and load-bearing at bends.”
Support and fixation are essential for the stable operation of vertical pipelines. According to the national standard “Code for Construction of Concrete Structures” GB 50666‑2011, both horizontal and vertical concrete pump pipelines shall be secured with supports. The connections between the supports and the pump pipelines, as well as between the supports and the structural elements, must be firmly fastened. It is strictly prohibited to connect pump pipelines or their supports directly to scaffolding or formwork systems to prevent safety accidents. In practical installation of vertical pipelines, each vertical pipeline should have at least one fixing point on walls or columns; during tunneling operations, when laying along tunnel walls, supports or pipe clamps should be installed at intervals of 2 to 3 meters.
Backflow prevention measures are employed to prevent concrete from flowing backward into the pump under its own weight. When conveying concrete upward, the total equivalent length of straight and bent sections in the horizontal pipeline at ground level should be no less than 20% of the vertical delivery height and no less than 15 meters. When installing vertically upward piping, the vertical pipe must not be connected directly to the pump outlet; instead, a horizontal section at least 15 meters long should be installed between the pump and the vertical pipe, equipped with a check valve (or shut-off valve). This buffer section effectively controls the excessive pressure exerted on the pump by the concrete in the vertical delivery line under gravity, thereby reducing the risk of backflow.
The load‑bearing design of bent pipes shall account for the self‑weight of the vertical pipe. The bend at the lower end of the vertical pipe should not be used as a support for the upper piping; instead, separate steel supports should be provided to carry the vertical pipe’s weight. In projects involving significant vertical conveying heights, both the forces exerted by the pump‑discharge pipe on the supports and the forces transmitted from the supports to the structure must be verified through structural analysis. If necessary, structural reinforcement should be implemented to ensure the safety and reliability of the support system.
II. Key Locations and Specific Measures for Supporting Vertical Pipelines
Support for the outlet buffer section. The delivery pipeline of a wet‑spraying carriage typically follows a layout of “straight pipe–bend–vertical pipe.” At the discharge end of the pump on a wheeled wet‑spraying carriage, a horizontal pipe is installed; a bend is connected at the top of this horizontal run to redirect the concrete flow vertically. Beyond the pump outlet, additional directional changes in the horizontal plane should be avoided to prevent significant pressure losses. The length of this horizontal buffer section lays the foundation for the stability of the vertical pipeline—longer horizontal runs reduce the impact experienced by the vertical pipe. Horizontal delivery pipes should be secured at regular intervals with brackets, pads, or suspension devices, ensuring smooth pumping while facilitating unclogging, assembly/disassembly, and cleaning.
Increased fastening at pipe bends. Pipe bends are the most highly stressed and vibration‑prone sections in a piping system. National standards explicitly require denser support spacing at pump‑discharge pipe bends. Pipe clamps or supports must be provided separately at both ends of each bend, and robust additional fixings should be installed at the bend itself. Since bending areas experience significant loads, supports in the bend‑transition zone should generally be spaced more closely; the piping should not be relied upon to bear any extra loads on its own.
Fixed installation along structural elements. Vertical pipelines may be routed along tunnel walls, columns, or other structural members, with pipe clamps secured to the structure using embedded fittings. On walls and columns, each pipe section shall have no fewer than one fixing point, and all floor‑level openings must be properly anchored. Vertical pipes should preferably be fixed to walls, columns, or to the embedded anchor points in floor slabs. At openings reserved in floor slabs or rock faces, auxiliary measures such as wooden plugs or clamping devices may be employed to enhance fixation reliability and prevent the pipeline from bouncing up and down under pressure pulsations.
Adaptive support between the tunnel wall and the rock strata. In tunnel construction, vertically upward‑extending pipelines are typically routed along the tunnel lining or steel arch supports. The supports are securely connected to the tunnel lining or steel arches, while bent and straight sections of piping are clamped to the tunnel wall or steel arches, ensuring that the gravitational loads of the pipeline and the conveyed concrete are reliably transferred to the supporting points. For temporary support systems, when vertical pipes are anchored to scaffolding, the scaffolding may be reinforced as needed to accommodate the additional loads imposed by the pipeline.
III. Safety Precautions and Notes
Prevent the support brackets from being interconnected with the scaffolding. The delivery pump pipes and their supports must not be directly connected to the scaffolding or formwork, to avoid a collapse of the scaffolding in the event of pipe rupture or vibration. The connections between the supports and the structure shall be independent and reliable.
Do not use the pipeline itself as a load-bearing element. The bend at the lower end of a vertical pipe shall not serve as a support for the upper pipe; instead, a separate steel support must be installed below to bear the full weight of the concrete when the vertical pipe is fully filled. Concrete pump pipes shall not be directly supported on reinforcing steel, formwork, or embedded components.
Configuration of check valves (shut-off valves). When the delivery height is relatively large—typically ≥100 m—the delivery pipe at the pump outlet should be equipped with a shut-off valve to prevent concrete backflow after pump shutdown and to facilitate temporary isolation of the pipeline during maintenance. In standard wet‑spraying rig operations, if the upward delivery height is substantial or the pumping duration is prolonged, it is likewise recommended to install a check valve to mitigate the impact of backflow on the pumping system.
Routine inspection and maintenance. Concrete pump pipelines and their supports shall be inspected and maintained regularly. Before each shift, the entire pipeline should be checked to ensure that all supports and pipe clamps are securely fastened, sealing rings are intact, and there is no significant thinning of the outer wall thickness at bent sections. If any support or clamp is found to be loose, it must be tightened promptly; pipes with excessive wear should be replaced without delay, and decommissioned pipes must not be reused in high-pressure vertical runs. At pipe joints, grout leakage is prohibited, and pipe clamps must be fully and securely tightened.
IV. Reference for Support Spacing and Positioning
Based on national standards and engineering experience, the support spacing for vertical pipelines may be determined according to the following table:
| Installation Location | Support Spacing | Special Requirements |
| Along the structure (wall/column/tunnel lining) | A fixed anchor point every 2–3 m | Each pipe section must have at least one fixed anchor point |
| At both ends of the bent pipe | Install supports immediately adjacent to each end | Increase the density of supports at the bend transition |
| Horizontal-to-vertical transition section | Supports installed every 1.5–2 m along the horizontal pipe | Horizontal pipe length not less than 15 m |
| At openings reserved in floor slabs or rock walls | Must be securely fixed at each floor level | Wooden plugs may be used to assist with clamping |
The above spacing values are general guidelines; in practical applications, they should be verified in conjunction with the equipment’s pumping pressure and the total elevation of the piping system. If necessary, increase the density of support points to ensure the stability and safety of the vertical piping.
In summary, the support system for the vertical pipeline of a fully automated wet‑spraying carriage centers on the following key measures: rigid bracket fixation, densified pipe clamping at bends, independent load-bearing supports, and the installation of check valves. By securely anchoring the brackets to the tunnel lining or rock strata, pipeline movement and sagging during pumping are eliminated; additional, closely spaced fixing points are provided at bend transitions and joints to absorb pulsation‑induced impacts; and lower‑mounted, independent steel supports bear the self‑weight of the vertical pipe. These measures effectively reduce the risk of accidents in the vertical conveying section. Furthermore, establishing a systematic inspection regime for vertical pipeline fixation—conducting checks at each shift and performing regular maintenance—can significantly lower the likelihood of pipe disconnection and rupture, thereby ensuring the continuous and safe operation of the wet‑spraying carriage during high‑altitude spraying tasks.
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