Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and...

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Concrete Pumping Applications

Transcript of Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and...

Page 1: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Concrete PumpingApplications

Page 2: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Concretepumping

Reliability, safety and efficiencyare more important than ever for the pumping of

ready-mixed concrete. Especially for deadline-

bound projects, conveying pipes must not fail.

Single-layer ST52 pipes will wear out within very

short periods of time. This results in high costs

for service providers in the ready-mixed

concrete industry because of downtime due to

repairs, service / maintenance work or the

replacement of components.

ESSER WERKE have developed and produced

conveying pipes, elbows and special delivery

line parts for truck-mounted concrete pumps,

truck mixers concrete pumps or concrete

distributing booms since 1980. The two-layer

ESSER TWIN PIPES achieve a service life,

which is significantly longer than ST52 pipes.

Our pipes are checked for their pressure

resistance at regular intervals. The hardness of

TWIN PIPE pipes is constant over the entire

pipe length so that service intervals can be

scheduled more easily. All of our products are

manufactured subject to the pump manu-

facturers' specifications.

Today, ESSER conveying pipes are used

globally.

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Page 3: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Concretepumping

Our partnersManufacturers from all parts of the world rely on

ESSER conveying pipe systems. We supply

boom pipes and deck pipes, elbows, reducers

and special delivery line parts for concrete

pumps to the following OEM manufacturers:

• Cifa

• Elba

• Jun Jin

• Liebherr

� Putzmeister

• Schwing

• Sermac

• and many other

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Page 4: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Boom pipes

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ESSER 900

The special hardening process and high-quality welding

process ensure that ESSER pipes achieve a service life,

which is many times longer than that of commonly available ST52 pipes with the same wall thickness. Boom pipes

shall not exceed the specified weight in order to ensure that the stability of the machine is not endangered. All

ESSER pipes are manufactured in accordance with the weight specifications by concrete pump manufacturers.

Conveying pipes for booms are available in two different quality levels. We recommend that you use the ESSER

900 XL pipe where you get extreme wear e.g. behind an 10-45° elbow. Those pipes have an extended inlet weld

collar to compensate the wear.

* Only for short distances at critical wear points inside the boom.

** Compared with commonly available ST52 pipes. Medium concrete.

ESSER 700Material Double layer, hardened inner pipe

Inlet Big Mouth weld collar, hardened inner ring

Outlet Big Mouth weld collar, hardened inner ring

Hardness (acc. Rockwell) Up to 63 HRC

Nominal diameter (DN) [mm] DN 100 DN 125

Weld collar size [inch] 4,5" SK 5,5" SK

Wall thickness [mm] 2,0 + 2,0 2,0 + 2,0

(Inside and outside wall) 2,5 + 2,0

Length [mm] 100 - 6000

Working pressure (P) [bar] 85

Service life factor* 5

Material Double layer, hardened inner pipe

Inlet Big Mouth weld collar, hard cast inner ring

Outlet Big Mouth weld collar, hard cast inner ring

Hardness (acc. Rockwell) Up to 67 HRC

Nominal diameter (DN) [mm] DN 112 DN 117 DN 125

Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK

Wall thickness [mm] 2,0 + 2,0 2,0 + 1,5 2,0 + 2,0

(Inside and outside wall) 6,3 + 1,5* 3,0 + 1,5

Length [mm] 100 - 6000

Working pressure (P) [bar] 85

Service life factor** 10

* Compared with commonly available ST52 pipes. Medium concrete.

Page 5: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Boom pipes

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ESSER 900 XLMaterial Double layer, hardened inner pipe

Inlet Big Mouth weld collar, hard cast inner ring

XL Flange extension

Outlet Weld collar, hard cast inner ring

Hardness (acc. Rockwell) Up to 67 HRC

Nominal diameter (DN) [mm] DN 112 DN 117 DN 125

Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK

Wall thickness [mm] 2,0 + 2,0 2,0 + 1,5 2,0 + 2,0

(Inside and outside wall) 3,0 + 1,5

Length [mm] 100 - 6000

Working pressure (P) [bar] 85

Service life factor* 10

* Compared with commonly available ST52 pipes. Medium concrete.

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The special hardening process and high-quality welding

process ensure that ESSER pipes achieve a service life,

which is enormous longer than the commonly available ST52 pipes. ESSER recommends standard deck pipes in

a thick-walled design. Thick-walled conveying pipes for the deck are available in two different quality levels:

ESSER 700

ESSER 900

Material Double layer, hardened inner pipe

Inlet Big Mouth weld collar, hardened inner ring

Outlet Big Mouth weld collar, hardened inner ring

Hardness (acc. Rockwell) Up to 63 HRC

Nominal diameter (DN) [mm] DN 100 DN 125

Weld collar size [inch] 5,5" SK 5,5" SK

Wall thickness [mm] 4,5 + 3,2 5,6+3,0

(Inside and outside wall)

Length [mm] 100 - 6000

Working pressure (P) [bar] 85

Service life factor* 5

* Compared with commonly available ST52 pipes. Medium concrete.

Material Double layer, hardened inner pipe

Inlet Big Mouth weld collar, hard cast inner ring

Outlet Big Mouth weld collar, hard cast inner ring

Hardness (acc. Rockwell) Up to 67 HRC

Nominal diameter (DN) [mm] DN 125

Weld collar size [inch] 5,5" SK

Wall thickness [mm] 5,6+3,0

(Inside and outside wall)

Length [mm] 100 - 6000

Working pressure (P) [bar] 85

Service life factor* 10

* Compared with commonly available ST52 pipes. Medium concrete.

Deck pipes

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Elbows

ESSER 700

ESSER 900

Since elbows are subjected to heavier wear than straight

pipes, ESSER supplies conveying elbows with a bigger

wall thickness in a two-layer design. The layout and geometry of the elbow are ideally suited for stress. The internal

layers of the 700 series are hardened. For the 900 series, the internal elbow is made of a particularly wear-resistant

cast alloy. Conveying pipes must not exceed the specified weight in order to ensure that the stability of the machine

is not endangered. All ESSER elbows are manufactured in accordance with the weight specifications by concrete

pump manufacturers.

Material Double layer, hardened inner elbow

Inlet Big Mouth weld collar, hardened inner ring

Outlet Big Mouth weld collar, hardened inner ring

Hardness (acc. Rockwell) Up to 63 HRC

Nominal diameter (DN) [mm] DN 100 DN 125

Weld collar size [inch] 4,5" SK 5,5" SK

Wall thickness* [mm] 5,0 + 3,2 7,0 + 4,0

(Inside and outside wall)

Angle [degree] 5° - 90°

Working pressure (P) [bar] 85

Service life factor** 5

Material Double Layer.

Inner elbow out of special hard cast alloy

Inlet Big Mouth weld collar, hard cast inner ring

Outlet Big Mouth weld collar, hard cast inner ring

Hardness (acc. Rockwell) Up to 67 HRC

Nominal diameter (DN) [mm] DN 112 DN 117 DN 125

Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK

Wall thickness [mm] 5,0 + 2,0 5,0 + 2,0 7,0 + 2,0

(Inside and outside wall)

Angle [degree] 5° - 90°

Working pressure (P) [bar] 85

Service life factor** 10

* The wall thicknesses depend on the geometry and can vary depending on the dimensions and angles.** Compared with commonly available cast elbows. Medium concrete.

* The wall thicknesses depend on the geometry and can vary depending on the dimensions and angles.** Compared with commonly available cast elbows. Medium concrete.

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Reducers

In reducers, flow speed and also the pressure is changing.

As a result, the wear increases towards the reducer outlet.

For this reason, we have optimized the wear protection at particularly critical points, especially for our reducers of

the 900 series.

ESSER 700

ESSER 900

* Compared with commonly available ST52 pipes. Medium concrete.

Material Compound steel, double layer,

hardened inner pipe

Inlet Double weld collar, hard cast inner ring

Inlet type SK or OEM specific

Outlet Big Mouth weld collar, hard cast inner ring

Hardness (acc. Rockwell) Up to 63 HRC

Nominal diameter (DN) [mm] DN 125 / 100 DN 150 / 125

DN 125 / 112

DN 125 / 117

Wall thickness [mm] 4,0 + 4,0

(inside- and outside wall)

Length [mm] > 500

Working Pressure (P) [bar] 85

Service life factor* 5

Material Double Layer.

Inner pipe out of cast alloy.

Inlet Hard cast inner ring

Inlet type SK or OEM specifi c

Outlet Big Mouth weld collar, hard cast inner ring

Hardness (acc. Rockwell) Up to 67 HRC

Nominal Diameter (DN) [mm] DN 150 / 117

DN 150 / 125

Wall thickness* [mm] 6,0 + 4,0

(Inside and outside wall)

Length [mm] > 500

Working Pressure (P) [bar] 85

Service life factor** 10

* The wall thicknesses depend on the geometry.** Compared with commonly available ST52 pipes. Medium concrete.

Page 9: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

ESSER TX with an integratedwear indicator

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InnovationsDue to the construction of the two-layer pipe, it is not possible to use an ultrasound measuring unit for measuring

the wall thickness. Therefore, the residual wall thickness needs to be measured manually using a measuring

probe. Our new TX system allows the use of a conveying pipe up to its maximum service life, and continuous

measuring is no longer necessary. When the wear layer of the internal pipe has been worn down, the laitance will

exit through small channels. This component must be replaced and should be reordered immediately in order to

ensure safety. The exit point is secured against laitance ejection using a metal clamp.

ESSER 900 TXBoom pipe

With an integrated wear indicatorfor ensuring maximum usage.

ESSER 700 TXReducer

With an integrated wear indicatorfor ensuring maximum usage.

Material Double layer, hardened inner pipe

Inlet Big Mouth weld collar, hard cast inner ring

XL Flange extension

Outlet Big Mouth weld collar, hard cast inner ring

Hardness (acc. Rockwell) Up to 67 HRC

Nominal diameter (DN) [mm] DN 112 DN 117 DN 125

Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK

Wall thickness [mm] 2,0 + 2,0 2,0 + 1,5 2,0 + 2,0

(Inside and outside wall) 3,0 + 1,5

Length [mm] 100 - 6000

Working pressure (P) [bar] 85

Service life factor* 10

* Compared with commonly available ST52 pipes. Medium concrete.

* Compared with commonly available ST52 pipes. Medium concrete.

Material Compound steel, double layer,

hardened inner pipe

Inlet Double weld collar, hard cast inner ring

Inlet type SK or OEM specific

Outlet Big Mouth weld collar, hard cast inner ring

Hardness (acc. Rockwell) Up to 63 HRC

Nominal diameter (DN) [mm] DN 125 / 100 DN 150 / 125

DN 125 / 112

DN 125 / 117

Wall thickness [mm] 4,0 + 4,0

(inside- and outside wall)

Length [mm] > 500

Working Pressure (P) [bar] 85

Service life factor* 5

Page 10: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Back-end kits

ESSER produces complete pump outlets for machine

types of different manufacturers.

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Examples of different back-end kits in ESSER 900 quality

Elbow 42° DN125

Reducer DN 150 / 125

Elbow 90° DN150with holder

Elbow 50° DN125with extension

ReducerDN150 / 125

Elbow 90°DN150

Swivel ElbowDN 180/150(Version 1)

Swivel ElbowDN 180/150(Version 2)

Connection elbow 14°DN 180

Swivel Elbow 90°DN 180 / 150(Version 1)

Swivel Elbow 90°DN 180 / 150(Version 2)

Elbow 45° DN125with extension

ReducerDN 150 / 125

Elbow 90°DN 150

Page 11: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Special components

We also manufacture special delivery line components in

two-layer design. We work closely with concrete pump

manufacturers in order to find tailored solutions for their specific requirements.

Elbow with extension Rib pipes

Impact- and turret elbow Multiplex elbows

Special elbows Step elbows

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Page 12: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

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Performance optimisation

Typically, concrete conveying pipes show uneven

wear. The reducers, elbows or straight pipes behind

elbows have different service lifes as compared to the

places in the line with less wear stress. Therefore, the

operating times on job-sites are not easy to schedule

because one cannot foresee when a component

is going to fail. Worn-out pipes must be provisionally

sealed on site. In such an event, it will be difficult, and

sometimes impossible, to retract (suck back) the

cleaning ball. Very often the entire pipeline was

replaced although the rest of the them would have

lasted much longer. The downtime, for frequent

ESSER 700.

For normal delivery volume or average wear we

recommend pipe components of the ESSER 700

series. All parts are manufactured in a two-layer

design. Our standard layout for efficient concrete

pumping and conveying.

ESSER 700 UPGRADE(ESSER 700 / ESSER 900)

For enhancing particularly wear-prone pipe points by

higher-quality components from the ESSER 900

series.

Example:

= Elbow after reducer

(ESSER 900 with extension)

= Turret Elbow (ESSER 900)

= Turret Pipe (thick walled type)

= Boom Crossing (ESSER 900)

= Impact Elbow

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2

3

4

5

1

2

3

5

5

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Page 13: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Performance optimisation

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replacement of individual pipes or premature

replacement of the entire pipeline increase both the

wear costs and the number of necessary service

intervals. ESSER components are adjusted to the

specific requirements of the individual wear points

inside the conveying pipe. Due to the use of different

qualities at critical points, a conveying pipe can be

optimised by being adapted to the individual

requirements.

ESSER 900.

The optimum solution for high delivery volume and

heavy wear stress. The almost even wear rate

ensures that this system is particularly efficient for

bigger concreting projects.

ESSER 900 / ESSER 900 XL.

Boom pipes behind elbows show up to 50% more

wear. Turbulence, which is created by the change of

direction in the elbow, specifically attacks the inlet area

of the pipe.

To solve the problem, we recommend the ESSER 900

XL. For all ESSER 900 XL pipes, only the inlet flanges

have been reinforced over a certain distance with a

thicker internal wall. The additional weight is minimal

and within the pump manufacturer's tolerance range.

Example:

= ESSER 900 XL1

1

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11

1

Page 14: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

Performance

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What is the performance

of your pipes…?

170 bar test pressure

ESSER pipes for concrete pumps are designed for an operating

pressure of up to 85 bar. Our pipes are tested for pressure

resistance at regular intervals.

Constant hardness

The hardness / strength of ESSER pipes is constant over the

entire pipe length. As a result, the pipes show even wear and their

service intervals can be scheduled easily.

No additional weight

ESSER pipes are designed according to manufacturer weight

specifications. Therefore, the compliance with the statics

characteristics of the machine is ensured in all possible machine

positions.

Standardised weld

A pipe is only as good as its weld. Our welding process is in

accordance with standards specifications.

Increased wear-resistance

The service life of ESSER TWIN PIPES is up to 25% higher

compared to other two-layer pipes on the market.

Please contact us for

further information!

+49 2902 896 0

Page 15: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

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Wear characteristics ofESSER pipes

0

2

4

6

8

10

Serv

ice

LIf

e (

in c

om

pa

riso

n)

ST52ESSER 400= 2 x ST52

ESSER 700= 5 x ST52

ESSER 900= 10 x ST52

SERVICE LIFE(Compared with commonly available ST52 pipes

of the same wall thickness)

Page 16: Concrete Pumping Applications - ESSER-WERKE€¦ · Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially

ESSER-WERKE GmbH & Co. KG

Zum Puddelhammer 25

59581 Warstein

Germany

Tel. +49 2902 896 0

Fax +49 2902 896 30

eMail [email protected]

Home www.esser-werke.de

LTB · Le Teyau Bi Metal

13 Avenue de l’Europe

67300 Schiltigheim

France

Tel. +33 3885 64 500

Fax +33 3885 64 711

E-Mail [email protected]

Home www.essertwinpipes.com

ESSER Partner

EM

120029 G

B 1

50331