For large-scale projects, nighttime construction, or projects with tight deadlines, concrete pump trucks may need to operate around the clock (rotating shifts, lighting, and consistent material supply). This construction model places extremely high demands on vehicles, personnel, management, safety, and maintenance. The following systematically explains the construction operations of concrete pump trucks, focusing on precautions and vehicle quality.
1.1 Personnel Rotation and Fatigue Management
Operators and drivers should be divided into multiple shifts, ensuring adequate rest time each shift to avoid fatigue and operational errors. Each unit should be equipped with at least three certified operators, and continuous operation time should not exceed four hours.
Nighttime construction significantly impacts vision, alertness, and reaction time. Therefore, a strengthened shift handover system should be implemented to ensure clear handovers and communication of equipment status, fault conditions, and material availability.
When necessary, a backup operator should be available to handle emergencies (e.g., physical discomfort, emergency repairs, etc.).
1.2 Safety and Environmental Conditions
At night or in low-light conditions, ensure adequate lighting: the pump truck's own lighting, safety indicators, and auxiliary construction site lighting. If required, a 360° LED lighting system (illuminance ≥ 200 lux) should be installed, and a strobe warning light should be installed at the boom end.
Avoid operating the deployment boom or deployment pipe in inclement weather (strong winds, heavy rain, lightning, etc.). Excessive wind force can cause the boom and pipeline to sway, resulting in excessive stress and accidents. Reference standards stipulate that deployment boom operation should be suspended if the average wind speed is approximately 10 m/s or higher.
In environments potentially affected by weather (slippery surfaces, poor visibility, accumulated water, mud, etc.), inspect the ground conditions and safe passages, ensure the vehicle's outriggers are securely mounted, and operate on a level or nearly level surface. If installed on a slope, adjust the vehicle's horizontal deviation to within a certain range (for example, no more than 3 degrees) to prevent overturning.
1.3 Material Supply and Concrete Quality Control
Concrete supply must be continuous and stable, and transportation times must be carefully controlled to prevent concrete from failing or segregating during transportation. Sufficient spare concrete trucks or buffer stocks should be available for 24-hour operation.
Monitor the remaining material in the hopper at all times during pumping, ensuring it never falls below the mixing shaft to prevent air inhalation and blockage.
Concrete mix proportions, slump, and aggregate size must strictly comply with construction design requirements, especially during nighttime or extended construction periods, as temperature fluctuations can affect concrete workability.
1.4 Monitoring Equipment and Equipment Conditions
Before operation, check for sufficient fuel, hydraulic oil, lubricating oil, and water tanks. At night, check that all key components are visible and operable in low-light conditions.
Check the hydraulic system for leaks, ensure that pipe connections are securely sealed, and check that hoses, safety belts, boom hinges, and rotating mechanisms are free of any abnormalities.
Frequently monitor the temperature and wear of pipes and distribution lines: Continuous operation can lead to component temperature increases, leading to rapid accumulation of wear and fatigue.
1.5 Outriggers, Fabric Boom, and Layout Safety
Outriggers must be fully extended and in place to ensure a stable support area. When using one outrigger, the span and load range of the outrigger on the working side must be strictly controlled.
The fabric boom must be deployed and folded according to the instructions (from the factory manual or technical specifications). Do not use the fabric boom to drag or lift non-concrete materials or objects.
If the vehicle body needs to be moved when the fabric boom is fully extended, first fold/secure the upper portion of the boom and control the movement speed.
1.6 Emergency and Maintenance Response Mechanism
Under 24-hour operation conditions, a clear fault reporting system, spare parts inventory, and maintenance personnel rotations must be in place. It is recommended to maintain a sufficient supply of spare parts for certain key components (oil seals, hoses, hydraulic valves, pump seals, etc.).
In the event of pipe blockage, hydraulic failure, or boom movement problems, operations must be stopped immediately, system pressure must be relieved, and inspection and repairs must be performed. Before any operation, the hydraulic system accumulator must be released and safety must be confirmed.
1.7 Regulations, Licenses, and Division of Responsibilities
Operators must hold a valid driver's license and special equipment operator's license and undergo professional training.
Implement company/construction site safety regulations, clearly defining the responsibilities of operators, supervisors, and maintenance personnel. Safety officer inspection records must be maintained for nighttime or 24-hour operations.
When purchasing or evaluating a pump truck for 24-hour continuous operation, multiple aspects must be evaluated, including the chassis, pumping system, distributing boom, durability, and safety features. The following are key requirements.
2.1 Chassis and Powertrain
The chassis must have sufficient strength and stability to maintain the structural safety of the vehicle and pumping system under prolonged high loads. The chassis and vehicle must have good rigidity, and the suspension and tires must have strong load-bearing capacity. The transmission, drive system, braking system, and cooling system must be reliable, with ample margins for continuous operation (high temperatures and prolonged heating).
The engine and cooling system must be designed for excellent heat dissipation to maintain safe temperature rises during high ambient temperatures or continuous pumping loads. The lubrication system must use high-quality fluid, and filters must be regularly replaced and cleaned.
Oil pumps and hydraulic systems must utilize components that are resistant to high temperatures and high pressures, have fast response times, and are highly reliable. Spare fluids and consumables (filter elements, seals, etc.) must be readily available.
2.2 Pumping System and Piping
The main pump structure must be sturdy and wear-resistant, and the pump body and valve materials must be wear-resistant and erosion-resistant.
The piping layout (from the pump outlet to the dispensing arm to the hose) should be as short and straight as possible. Hose connection points and interfaces must be sturdy and well-sealed, and equipped with safety straps and anti-drop devices. Pipe diameters and wall thicknesses must be selected in accordance with design requirements (as specified in the pump truck manual) and must not be arbitrarily modified.
2.3 Dispensing Arm Structure and Mechanism
The dispensing arm's extension, folding, and rotation mechanisms must be smooth and reliable, with sufficient hydraulic and torque headroom for stable operation and fatigue resistance.
The outrigger system should be robustly designed, with extended travel and span for the telescopic outriggers, ensuring stable deployment. In single-sided support or sloped operations, clear markings and protective structures should be provided to ensure the operator is properly positioned for the outriggers and load.
2.4 Safety Features and Monitoring Devices
The equipment should be equipped with necessary safety features, such as hopper screens, guardrails, a fabric boom locking mechanism, an emergency stop button, a boom hydraulic lock, and a fabric hose safety belt.
Vibration, temperature, pressure, and load monitoring sensors should be installed as necessary to provide real-time system status and prompt alarms. Reliable lighting and visual aids are particularly important for nighttime operations.
2.5 Durability and Maintenance Ease
Components should be of high quality, with durable welds, steel plate thickness, and structural finishes. Key joints (such as boom hinges, outrigger sliding surfaces, and hydraulic cylinders) should be easily accessible for lubrication and replacement of worn parts.
The space layout and maintenance access should facilitate routine maintenance tasks such as inspection, refueling, filter replacement, and exhaust. Easy to operate at night or in emergency situations.
2.6 Reliability and Spare Parts Support
The pump truck brand or manufacturer should have a good reputation and service network, ensuring timely spare parts supply. Key components such as the engine, pump body, and hydraulic pumps and valves should be quickly replaced or repaired in the event of a malfunction.
When purchasing, check whether the manufacturer provides inspection reports, type test records, and durability test records for the vehicle and key components to assess its continuous operating capability.
2.7 Environmental and Regulatory Compliance
Considering the construction location (such as high temperatures, humidity, cold weather, and coastal corrosion), the vehicle's materials and corrosion, rust, and sealing properties must be compatible with the local environment. Nighttime construction may also involve noise and light pollution regulations, which must comply with local construction management requirements.
Traffic and construction safety regulations must be met, such as vehicle road permits, special equipment operating licenses, speed limits, and lighting markings.
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Key points of attention |
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Driver/operator |
Be familiar with the vehicle manual and the pump truck operating manual; unfold/fold the fabric boom and outriggers strictly according to regulations; enhance safety awareness at night; promptly check the lubrication, hydraulic, and pipeline status; report faults promptly in case of abnormalities; pay attention to shift handovers and fatigue management; and participate in continuous training. |
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When selecting a model, consider pumping capacity, boom length, outrigger configuration, chassis stability, and parts availability; look at vehicle testing and durability performance; pay attention to the manufacturer's after-sales service capabilities and spare parts support; and consider the total cost of ownership under continuous operation (maintenance, fuel, filter elements, replacement of wearing parts, etc.). |
24-hour continuous construction is a challenge for concrete pump trucks and their operators. Any negligence could lead to safety accidents, quality issues, or equipment damage. Only with effective personnel management, safety systems, equipment quality, and maintenance can the efficiency advantages of concrete pump trucks be fully utilized while ensuring project quality and safety.
If you have any questions about operating concrete pump trucks, or would like to customize a concrete pump truck, please contact us. We offer custom concrete pump truck services.
