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Pipeline Layout Method for Long-Distance Pumping with Truck-Mounted Concrete Pumps
Release time:
2026-09-07
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Summary:
In long-distance concrete pumping operations, the rational layout of the delivery pipeline for truck‑mounted and trailer‑mounted pumps is critical to the success of the pumping process. Excessive bends in the pipeline, improper pipe diameter selection, or inadequate securing can lead to a sharp increase in pumping pressure loss; in severe cases, this may result in pipe blockages or even pipe bursts. This paper systematically outlines the key considerations for pipeline layout in long-distance pumping, covering pipe diameter selection, horizontal and vertical routing, support and anchoring, and the configuration of bends.
I. Matching Pipe Diameter Selection with Pumping Capacity
Truck‑mounted pumps (trailer pumps) typically use delivery hoses with an inner diameter of 125 mm, whereas truck pumps generally employ hoses with an inner diameter of 150 mm. For long‑distance pumping, the appropriate hose diameter should be selected in conjunction with the maximum size of the concrete coarse aggregate: when the maximum aggregate size does not exceed 25 mm, a delivery hose with an inner diameter of at least 125 mm may be used; when the maximum aggregate size is no greater than 40 mm, a delivery hose with an inner diameter of at least 150 mm should be employed. In some regions, concrete containing coarse aggregate with a maximum size of 31.5 mm is used; although 125‑mm hoses can still be employed for such mixes, they result in significantly higher wear on both the pump and the hose. For long‑distance pumping, it is advisable to prioritize 150‑mm hoses to minimize resistance. The wall thickness of the hose must be matched to the pumping pressure; near the pump, high‑quality thick‑walled tubing should be used, and the pump outlet should not be connected directly to a bent pipe.
Concrete pump pipes should be selected based on a comprehensive assessment of factors such as the pump model, mix properties, total output, delivery distance, and coarse aggregate size. In special projects, trailer pumps may also use 150 mm‑diameter pipes; in such cases, transition fittings can be employed to accommodate changes in pipe diameter. Pump pipe connections must be tight, and pipe bends should be smooth to minimize pressure loss.
II. Straight Laying and Fixing of Horizontal Pipelines
Horizontal pumping pipelines should be laid as straight as possible to minimize concrete flow resistance and reduce the risk of pipe blockage. When bends are unavoidable, keep the number of bends to a minimum, and use 90° bends with a radius of at least 1 meter. Do not connect more than 6 meters of straight pipe immediately downstream of the flexible hose, and ensure that the hose is bent at an angle of no less than 90° during operation. In hot, sunny conditions, cover the pipeline with wet burlap or straw bags and water it regularly to cool it down; in cold weather, implement thermal insulation measures.
Horizontal conveying pipelines shall be secured at regular intervals using supports, pads, or hangers; they must not be directly supported on reinforcing steel, formwork, or embedded components. For long‑distance pumping, concrete anchor blocks shall be cast every 10 m to stabilize and secure the pump pipe. Both horizontal and vertical pump pipes shall be fixed with supports, and all connections between the supports, the pump pipes, and the structure must be firm and reliable; direct attachment to scaffolding or formwork is strictly prohibited.
III. Check Valves and Buffer Arrangements for Vertical Piping
When pumping vertically upward, the vertical delivery pipe must not be directly connected to the pump outlet. The total equivalent length of straight and bent sections of the horizontal ground‑level delivery pipe should be no less than 20% of the vertical delivery height and shall not be less than 15 m. This buffer section effectively limits excessive back pressure on the pump caused by the self‑weight of the concrete in the vertical pipe. To prevent concrete from flowing backward after the pump is stopped, a check valve (or shut-off valve) should also be installed near the pump on the horizontal pipeline, and when the delivery height exceeds 100 m, a shut-off valve should be provided at the pump discharge port.
When pumping upward to a height exceeding 20 m, the bottom bend of the vertical section may be tapped with a wooden hammer; if the sound is dull, the bend should be disassembled to remove any large aggregates that may have accumulated. Vertical pipelines shall be securely anchored at each floor or at the openings provided in the floor slabs using brackets or wooden wedges. The ratio of horizontal delivery pipe length to vertical delivery height should preferably be maintained at 0.2.
IV. Venting of Inclined and Downward Pipelines
When installing downward‑sloping pipelines, a horizontal section should be added at the discharge outlet, with a length no less than five times the elevation difference of the sloped run. For steeper slopes, an air‑vent valve should be installed at the upper end of the slope to prevent accelerated concrete flow under its own weight, which could lead to pipe emptying. When conveying concrete through inclined or vertically downward‑running pump lines with an elevation difference exceeding 20 m, a straight or bent pipe section should be provided at the lower end, and its total equivalent length should not be less than 1.5 times the elevation difference.
V. Reinforcement of Supports at Pipe Bends and Routine Inspections
The bent‑pipe turning sections experience significant stresses, so supports should be arranged more densely. The structural integrity at support locations must be verified, and reinforcement measures should be implemented where necessary. Conveying pipelines shall be adequately supported and secured; wooden pads must be installed between the pipeline and fixed structures to provide cushioning, and direct contact with reinforcing steel or formwork is prohibited. Pipe joints and clamps must be tightly fastened and sealed to prevent grout leakage. Following installation, a pressure‑test shall be conducted. Prior to each use, inspect the wall thickness to ensure it meets or exceeds the minimum specified by the manufacturer.
The delivery pump pipes and their supports shall be regularly inspected and maintained; any pipes, clamps, sealing rings, or other components whose wear exceeds the specified limits must be replaced promptly. Pipe joints and sealing rings must be intact and undamaged; grout or air leakage is a direct cause of pump blockages and must be strictly controlled on the construction site. During concrete pumping, if the pipeline vibrates or shifts, the vertical pipe must be securely braced with steel scaffolding, and may only be used after passing a daily inspection.
VI. Lubrication Prior to Pumping and Process Monitoring
Before pumping concrete, it is advisable to first pump cement mortar to lubricate the pump and delivery pipeline, then begin concrete pumping. Start at a slow rate and gradually increase speed; once the system is running smoothly, proceed at the normal pumping rate. This procedure is particularly important for preventing pipe blockages. During pumping, inspect the pipeline along its entire length for signs of wear, loose clamps, and damaged seals or leaks of grout and air. When laying long pipelines, minimize the number of bends and flexible hoses, as well as the degree of bending, to maintain stable pumping pressure. The pump’s delivery pipes and their supports should be regularly inspected and maintained to ensure the pipeline system remains in optimal condition.
Conclusion
The rational layout of long-distance pumping pipelines for truck‑mounted pumps requires comprehensive control across multiple aspects, including pipe diameter matching, straight‑line routing, the provision of expansion loops, densification of supports, and proper venting. Such arrangements must be implemented in strict accordance with relevant codes and standards. Based primarily on GB 50666‑2011 and JGJ/T 10, and taking into account actual project conditions, selecting appropriately sized pipes, optimizing the horizontal and vertical pipeline routing, and reinforcing the fixation and maintenance at bends can significantly reduce the risk of blockages and ensure the continuous, stable operation of long‑distance pumping.
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