As an indispensable piece of equipment in modern construction, the standardization and safety of concrete pump truck pouring operations are directly related to project quality and efficiency. This article systematically introduces the concrete pump truck pouring operation process, technical specifications, common problem prevention measures, and safety precautions, providing a reference for concrete pump truck pouring operations.
1.1 Pre-Operation Preparations
Equipment Inspection: Before operation, a comprehensive inspection should be conducted, including engine oil, water, hydraulic system, electronic control, safety devices, outrigger function, remote control equipment, etc. Ensure that the pump truck's exterior is free of significant wear, impact marks, or cracks. Check that key components such as the engine, hydraulic system, and transmission are functioning properly, with no leaks or abnormal noises. Check tire pressure, wear, and wheel hub condition.
Oil and Water Inspection: Verify that fuel, lubricating oil, hydraulic oil, and other oils are sufficient and clean. Check that cooling water is sufficient and clean, and ensure that the radiator is not clogged.
Site Preparation: Clear the route for concrete trucks at the construction site, ensuring it remains clear of obstructions. Allow ample space for the trucks to park and avoid disrupting other operations.
1.2 Site Arrangement
The pump truck should be positioned on a flat, stable surface to avoid operating on slopes. If operating on a slope, ensure the truck is level (within 3 degrees) using the outriggers. Install vehicle stops, anti-slip mats, and outrigger blocks or metal plates to prevent tipping.
1.3 Environmental and Safety Risk Assessment
Check for overhead power lines. The pump boom extension area should be kept a safe distance from high-voltage power lines. Ensure that personnel are on guard and monitoring during operation.
Avoid approaching deep pits or edges with the pump truck. Follow the "1:1" setback principle: retreat one foot for every 1 foot of depth.
1.4 Pump Startup Procedure
Start the engine according to the manufacturer's instructions and ensure it operates normally.
Properly connect the delivery hose to the pump truck's delivery hose port and ensure the connection is secure.
Before the first pumping, pump 0.5 to 1 cubic meter of mortar. Leave some mortar in the hopper above and below the hopper axis. Pump it in after the concrete is added.
Start the drum mixer pump and run it dry. In cold weather, the dry run time should be extended. The hydraulic oil temperature must reach 15°C before pumping.
1.5 Concrete Pumping Process
Speed Control: During the first pumping, if the pipe resistance is high, pump at a low speed. Gradually increase the speed after normal operation. If signs of pipe blockage or low slump occur, reduce the speed immediately.
Residual Material Management: Residual material in the hopper should be above the mixer shaft (to prevent air ingestion) but not above the guardrail (to facilitate cleaning of oversized aggregate).
Pressure Monitoring: If the pressure gauge reading suddenly rises, immediately reverse the pump for 2-3 strokes and then pump forward. If repeated attempts are ineffective, dismantle the pipe and clean it.
1.6 Safety and Efficiency During Pumping
Pumping pressures are high. If the pipeline becomes unstable, blocked, or ruptured, it could cause serious safety hazards such as concrete spillage. Real-time monitoring of pressure changes is essential. If resistance is detected, operation should be interrupted and cleaning measures implemented immediately.
Pipeline ends and joints should be secured with safety chains, fall arresters, and lanyards to prevent injury from falling components.
1.7 Completion of Pumping Operations
After completing concrete pumping, shut down the engine according to the manufacturer's instructions.
If pumping is stopped for more than 5 minutes, the concrete in the end hose must be drained. Otherwise, dehydration of the concrete in the end hose will cause violent concrete ejection upon re-pumping.
Disassemble the pipeline and thoroughly clean it to prevent concrete residue from clogging the pipeline.
1.8 Safety Precautions for High-Risk Activities
When draining the pipeline, if compressed air is used, stand at a safe distance and avoid using double-ended or double-S fittings to prevent the sudden release of high-pressure air from violently swinging the hose back and injuring people.
Standing in front of the hose outlet is strictly prohibited to avoid injury from flying objects.
2.1 Operator Qualification Requirements
Operators must hold relevant job qualification certificates, have operating experience, and complete professional training.
They must be familiar with the performance and structure of concrete pump trucks and understand the basic operating principles and operating requirements of the equipment.
They must be in good health and must not operate under the influence of alcohol, tobacco, or psychotropic substances that could affect work safety.
2.2 Equipment Technical Standards
According to GB/T 30195-2013 "Concrete Pump Trucks":
The gross weight of the machine must not exceed 85% of the permissible chassis load.
The height error rate of the boom when horizontally extended must be less than 1.5%.
The electrical system protection level must meet IP54 standards.
The hydraulic oil temperature rise limit is set at 45°C.
2.3 Piping Layout Specifications
Adhere to the principle of "short distance, few elbows, and large elbows." The curvature radius of 90° pipe bends must be ≥ 500mm.
At the pump outlet cone, first connect a straight pipe ≥500mm long, then an elbow, to avoid direct connections.
The horizontal pipe length should be ≥15% of the vertical pipe length. For high-rise pumping, a shut-off valve should be installed in the horizontal section.
3.1 Causes and Prevention of Pipe Blockage
Main Causes:
Excessive concrete slump or segregation.
Improper pumping speed.
Debris or concrete debris in the pipe.
Excessive downtime causes initial setting of the concrete.
Preventative Measures:
Control concrete slump: Adjust according to the pumping height. Do not add water on-site.
Optimize aggregate grading: Coarse aggregate particle size ≤ 1/4 (crushed stone) or 1/3 (pebbles) of the pipe diameter.
Lubricate the pipe with cement mortar before the first pumping (0.5 m³ of mortar for every 200 m of horizontal pipe).
Downtime should be ≤ 5-10 minutes. During this time, run the pump forward and reverse 4-5 times every 5 minutes.
3.2 Preventing Operational Errors
Distraction: Maintain full attention during operation and monitor the pump pressure gauge readings.
Improper Speed Selection: Pump at a low speed for the first pumping operation. Increase the speed appropriately after confirming that there are no abnormalities.
Improper Residual Material Control: Concrete in the hopper should not accumulate excessively and should be lower than the guardrail to facilitate the removal of oversized aggregate.
3.3 Wearing Appropriate Personal Protective Equipment (PPE)
Workers should wear hard hats, safety glasses, protective gloves, steel-toed shoes, cement boots, dust masks (if dust is present on site), and long-sleeved shirts and long pants to avoid direct skin contact with wet, alkaline concrete, which may cause burns.
3.4 Skin and Eye Protection and Treatment
If concrete comes into contact with skin, immediately wash with a neutral or slightly acidic solution (such as dilute vinegar) and seek medical attention immediately to avoid burns or infection.
4.1 Worksite Safety Requirements
Pumping equipment should be placed a certain distance from the edge of the foundation pit.
Pipeline routing for horizontal pumping should be rational, and the pipes and pipe supports must be securely fastened.
It is strictly forbidden to connect vertical pipes directly to the pump outlet. A horizontal pipe with a length of at least 10 meters should be connected to the front end of the vertical pipe.
The parking area for the pump truck must be hardened, stable, and secure, with good drainage facilities to prevent collapse.
4.2 Personal Safety
No one should stand within 1 meter of the pipe on either side to prevent injury from swinging pipe.
No one should stand within 30 meters of the pipe outlet to prevent air from forming in the pump and the pumped aggregate from high pressure from injuring people.
Operators must wear appropriate personal protective equipment, such as a hard hat, protective shoes, safety glasses, and gloves.
4.3 Emergency Measures
Fire: Immediately disconnect the power supply and use fire extinguishing equipment to extinguish the fire. If the fire gets out of control, call the police and evacuate personnel immediately.
Electrical Leakage: Immediately disconnect the power supply, provide first aid to the injured, and notify maintenance personnel for inspection.
Equipment overturns: Immediately cut off the power supply, quickly evacuate the danger zone, and notify rescue teams for emergency assistance.
4.4 Operational Taboos
Do not use the pump boom in place of a lifting tool.
Do not operate pumping equipment at night or in poor lighting conditions. Operate in sufficient light, with lighting assistance and a supervisor present.
Do not rashly increase the pumping pace; the pace should be appropriately matched to the concrete pouring and vibrating rhythm to prevent pressure runaway.
Do not work on filters or vulnerable work platforms to prevent people from falling into the mixer and causing serious injury or death.
Do not operate the pump boom in wind speeds exceeding 10 m/s or during thunderstorms to avoid electric shock or slipping accidents.
JGJ/T 10-2011 "Technical Specifications for Concrete Pumping Construction."
GB/T 30195-2013 "Concrete Pump Trucks."
GB/T 39757-2021 "Construction Machinery and Equipment - Safe Use of Concrete Pumps and Pump Trucks."
QC/T 718-2013 "Concrete Pump Trucks."
Through these systematic operating guidelines and safety regulations, concrete pump truck operators can fully understand the technical requirements of pumping operations, effectively prevent operational risks, and ensure a safe and efficient construction process. During actual operations, operators should strictly adhere to the equipment manufacturer's operating manual and relevant industry standards, perform regular equipment maintenance, and continuously improve their operating skills and safety awareness.
Concrete pump truck pouring is a highly professional and safety-critical construction process. Comprehensive pre-production planning, safety assessments, equipment inspections, training procedures, and emergency response plans are essential to ensure operational safety. Key controls include equipment layout, pressure control during pumping, environmental risks (such as electrical wires and slopes), personal protection, and cleanup and finalization. Strict adherence to operating regulations and safety precautions can minimize construction risks, ensure the safety of personnel and equipment, and ensure an efficient and smooth pouring process.
If you have any questions about concrete pump trucks and pouring, or want to customize a concrete pump truck, please contact us and we will provide customized services.
