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21 JUNE 2025
During the operation of concrete pump equipment, frequent replacement of wearing parts is necessary due to their limited lifespan.
The wearing parts of a concrete pump truck mainly include concrete pipe tubes, S valve pipe tubes, spectacle wear plates, cutting rings, pistons, concrete cylinders, rubber hoses, mixing blades, etc. The consumption of these wearing parts is significant, making cost control crucial to reducing replacement expenses.
Each spare part on a concrete pump truck serves a unique purpose and operates on different working principles. Moreover, their materials vary, leading to differences in lifespan.
This article delves into the service life of concrete pump spare parts, emphasizing the importance of optimizing costs in maintenance and replacement.
The lifespan of concrete pump pipes depends greatly on factors such as material composition, wall thickness, and concrete grade. Wear-resistant pipes are primarily determined by their raw materials, with significant variations in service life based on material type. For instance, 16Mn material outperforms ST52, while 55Mn is superior to 16Mn. Additionally, hardened and twin-wall pipes boast longer lifespans compared to single concrete pipes.
Ground pump pipes typically last between 5,000 to 20,000 cubic meters, while hardened and twin-wall pump pipes can endure between 30,000 to 80,000 cubic meters. The primary cause of pipeline wear is the flow of concrete.
Higher concrete grades contribute to more severe wear, and thicker pipe walls enhance wear resistance. Failing to replace worn concrete pumping pipes promptly can lead to safety hazards during construction.
When using concrete pump equipment, frequent replacement of wearing parts is necessary due to their limited lifespan. These parts include concrete pipe tubes, S valve pipe tubes, spectacle wear plates, cutting rings, pistons, concrete cylinders, rubber hoses, and mixing blades. Given the substantial consumption of wearing parts, cost control is vital to minimizing replacement expenses.
Each spare part serves a unique purpose and operates on different principles. Additionally, the materials used in concrete pump accessories vary, resulting in differing lifespans. This article provides insights into the service life of concrete pump spare parts, highlighting the importance of optimizing costs in maintenance and replacement processes.
Concrete pipes and elbows are crucial spare parts for concrete pumps, with two main types: single elbows and twin-wall elbows. Single elbows typically last around 10,000 cubic meters (cbm), while twin-wall elbows offer a significantly longer lifespan of over 25,000 cbm.
Twin-wall elbows consist of two layers: a high-hardness wear-resistant inner layer and a Q235 material protective outer layer. These layers are nested together, with SK148 flanges welded at both ends. On the other hand, single elbows are cast and equipped with 148 flanges at both ends.
The cubic meter capacity of twin-wall elbows ranges from 30,000 CBM to 80,000 CBM, primarily determined by the material of the inner layer. Different materials exhibit varying levels of wear resistance, despite similar processing methods.
Overall, twin-wall pipes demonstrate a longer lifespan compared to single-wall pipes, making them a preferred choice for durability and longevity in concrete pump operations.
The spectacle wear plate serves as a vital spare part within the pumping distribution valve, linking to the concrete delivery cylinder. It operates in conjunction with the swing cylinder, allowing the S valve tube to swing across the delivery cylinder while the cutting ring interacts with the wear plate on the S valve pipe.
Commonly used materials for manufacturing wear plates include tungsten, high-chromium alloy, carbide, and others. Depending on the material, the service life of wear plates can range from 20,000 CBM to 100,000 CBM or more.
Wear plates are critical components in concrete pumps, and timely replacement is essential upon damage or failure to ensure the uninterrupted operation of the entire equipment system.
The cutting ring is a crucial component of a concrete pump, taking on a ring shape and executing shearing motions during operation, earning its name. Presently, cutting rings are crafted from materials such as tungsten, cast alloy, carbide, among others, offering service lives ranging from 20,000 CBM to 100,000 CBM.
Working in tandem with the wear plate, the cutting ring experiences wear as particles in the abrasives increase, leading to wear gap expansion. Once the gap reaches a critical point, significant slurry leakage can disrupt construction activities.
Regular adjustments to the cutting ring's orientation and tightening of the specially shaped nut after the concrete pump operates for a duration can significantly extend the service life of both the wear plate and cutting ring. These maintenance measures are vital for optimizing equipment performance and durability.
The piston ram serves as the reciprocating component within the engine block of a concrete pump truck, typically made of rubber. Over time, piston rams wear out, leading to a loss in sealing performance.
Excessive wear on the piston ram, if not promptly replaced, can result in subpar pumping of concrete and potentially lead to equipment failures.
The replacement timeframe for the concrete pump delivery cylinder piston varies based on factors like usage duration, frequency of use, and working environment. Generally, under normal conditions, the service life ranges from 20,000 to 30,000 cubic meters of concrete. However, the specific replacement schedule should be determined based on individual circumstances. It's advisable to conduct regular checks on piston wear and replace them as needed to maintain optimal performance and prevent potential issues.
Sponge cleaning balls are essential components in concrete pumps, crafted from pure natural rubber known for its high resilience and superb wear resistance. These balls serve as cleaning agents for various concrete pump pipes and rubber hoses, effectively removing dirt and debris from the pipelines and prolonging their lifespan.
Sponge cleaning balls are typically categorized into three material types: soft, hard, and medium-soft. Soft cleaning balls offer low friction during cleaning but have a shorter service life. Hard cleaning balls, on the other hand, are suitable for cleaning tough surfaces and yield excellent cleaning results.
It's important to note that using excessively hard sponge cleaning balls can lead to excessive friction, resulting in significant wear within the pipeline system. Therefore, selecting the appropriate cleaning ball based on the cleaning requirements and pipeline conditions is crucial for optimal cleaning performance and pipeline maintenance.
The concrete pump rubber hose plays a crucial role in transporting concrete during construction, handling high pumping pressures and the complex properties of concrete, along with external environmental factors.
Due to these influences, rubber hoses are prone to aging and wear, necessitating careful consideration of their service life and replacement cycles during construction projects. The replacement cycle should be adjusted flexibly based on specific circumstances. Typically, concrete pumps with higher pumping volumes may require more frequent hose replacements.
When selecting a rubber hose, it's important to consider factors such as the moisture content and particle size of the concrete being pumped. Choosing a hose that suits these criteria can help extend its service life and ensure efficient concrete transportation during construction projects.
The service life of concrete pump seal kits can vary due to various factors. While long-term wear and tear are rare causes of seal kit failure, other factors like particle concentration, temperature, corrosive substances, and environmental conditions can lead to premature failure.
Proper selection, installation, and maintenance of seal rings are essential to extend their service life and enhance the reliability of your concrete pump truck.
It's crucial to have spare seal rings or seal kit packages available. However, storing seal kits for extended periods is not recommended. If stored for over a year, it's advisable to check the components for normalcy before use to ensure the safety and functionality of the concrete pump truck.
The delivery cylinder is a critical component of a concrete pump. Its interior typically features a high-chromium layer, offering a service life of approximately 80,000 to 150,000 cubic meters.
During operation, the chromium-plated layer of the delivery cylinder and the piston undergo constant friction. Additionally, the flowing concrete can cause damage to the chromium-plated layer, leading to a reduction in the cylinder's service life.
The insufficient hardness of the chromium plating layer makes it susceptible to scratches from sand and gravel particles in the concrete, resulting in a rough working surface and accelerated cylinder wear. Therefore, timely replacement of the piston and regular inspection of the high chromium layer inside the cylinder are essential maintenance practices to ensure optimal performance and longevity of the delivery cylinder.
The S valve pipe is a crucial spare part in the concrete pump's pumping system. It features different surfacing wear-resistant layers inside, with a service life ranging from 20,000 to 80,000 cubic meters. If the wear-resistant layer inside is worn, it should be removed and repaired to extend its service life.
As concrete passes through the S valve pipe, uneven friction on the inner wall can lead to varying degrees of damage, ultimately reducing the pipe's service life.
During replacement, it's important to ensure the part number matches and the installation position is accurate to avoid any potential hazards. Misalignment or incorrect installation can result in severe accidents.
As the usage of concrete pump parts increases, many of these spare parts gradually age, impacting daily operations and potentially endangering the safety of individuals in the vehicle. Therefore, regular replacement of spare parts is necessary.
It's essential to handle spare parts with care, conduct frequent checks, and maintain them regularly. Just like the saying goes, "The body is the capital of revolution," a concrete pump truck also requires proper care for its spare parts to ensure its optimal performance and safety.
If you're in need of concrete pump spare parts, feel free to reach out to us. We are a professional supplier offering one-stop supply services for Putzmeister, Schwing, Zoomlion, Sany equipment, ensuring you get the right parts for your concrete pump needs.
