Concrete Pumping Applications

Concrete Pumping Applications

Concrete pumping Reliability, safety and efficiency are more important than ever for the pumping of ready-mixed concrete. Especially for deadlinebound 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 980. 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 manufacturers' specifications. Today, ESSER conveying pipes are used globally. 2

Concrete pumping Our partners Manufacturers 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 3

Boom pipes 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 0-45 elbow. Those pipes have an extended inlet weld collar to compensate the wear. ESSER 700 Double layer, hardened inner pipe Big Mouth weld collar, hardened inner ring Big Mouth weld collar, hardened inner ring Hardness (acc. Rockwell) Up to 63 HRC Nominal diameter (DN) [mm] DN 00 DN 25 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] 00-6000 Working pressure (P) [bar] 85 Service life factor* 5 * Compared with commonly available ST52 pipes. Medium concrete. ESSER 900 Double layer, hardened inner pipe Hardness (acc. Rockwell) Up to 67 HRC Nominal diameter (DN) [mm] DN 2 DN 7 DN 25 Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK Wall thickness [mm] 2,0 + 2,0 2,0 +,5 2,0 + 2,0 (Inside and outside wall) 6,3 +,5* 3,0 +,5 Length [mm] 00-6000 Working pressure (P) [bar] 85 Service life factor** 0 * Only for short distances at critical wear points inside the boom. ** Compared with commonly available ST52 pipes. Medium concrete. 4

Boom pipes Double layer, hardened inner pipe XL Flange extension Weld collar, hard cast inner ring Hardness (acc. Rockwell) Up to 67 HRC Nominal diameter (DN) [mm] DN 2 DN 7 DN 25 Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK Wall thickness [mm] 2,0 + 2,0 2,0 +,5 2,0 + 2,0 (Inside and outside wall) 3,0 +,5 Length [mm] 00-6000 Working pressure (P) [bar] 85 Service life factor* 0 * Compared with commonly available ST52 pipes. Medium concrete. ESSER 900 XL 5

Deck pipes 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 Double layer, hardened inner pipe Big Mouth weld collar, hardened inner ring Big Mouth weld collar, hardened inner ring Hardness (acc. Rockwell) Up to 63 HRC Nominal diameter (DN) [mm] DN 00 DN 25 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] 00-6000 Working pressure (P) [bar] 85 Service life factor* 5 * Compared with commonly available ST52 pipes. Medium concrete. ESSER 900 Double layer, hardened inner pipe Hardness (acc. Rockwell) Up to 67 HRC Nominal diameter (DN) [mm] DN 25 Weld collar size [inch] 5,5" SK Wall thickness [mm] 5,6+3,0 (Inside and outside wall) Length [mm] 00-6000 Working pressure (P) [bar] 85 Service life factor* 0 * Compared with commonly available ST52 pipes. Medium concrete. 6

Elbows 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. Double layer, hardened inner elbow Big Mouth weld collar, hardened inner ring Big Mouth weld collar, hardened inner ring Hardness (acc. Rockwell) Up to 63 HRC Nominal diameter (DN) [mm] DN 00 DN 25 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 ESSER 700 * The wall thicknesses depend on the geometry and can vary depending on the dimensions and angles. ** Compared with commonly available cast elbows. Medium concrete. Double Layer. Inner elbow out of special hard cast alloy Hardness (acc. Rockwell) Up to 67 HRC Nominal diameter (DN) [mm] DN 2 DN 7 DN 25 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** 0 ESSER 900 * The wall thicknesses depend on the geometry and can vary depending on the dimensions and angles. ** Compared with commonly available cast elbows. Medium concrete. 7

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 Compound steel, double layer, hardened inner pipe Double weld collar, hard cast inner ring type SK or OEM specific Hardness (acc. Rockwell) Up to 63 HRC Nominal diameter (DN) [mm] DN 25 / 00 DN 50 / 25 DN 25 / 2 DN 25 / 7 Wall thickness [mm] 4,0 + 4,0 (inside- and outside wall) Length [mm] > 500 Working Pressure (P) [bar] 85 Service life factor* 5 * Compared with commonly available ST52 pipes. Medium concrete. ESSER 900 Double Layer. Inner pipe out of cast alloy. Hard cast inner ring type SK or OEM specifi c Hardness (acc. Rockwell) Up to 67 HRC Nominal Diameter (DN) [mm] DN 50 / 7 DN 50 / 25 Wall thickness* [mm] 6,0 + 4,0 (Inside and outside wall) Length [mm] > 500 Working Pressure (P) [bar] 85 Service life factor** 0 * The wall thicknesses depend on the geometry. ** Compared with commonly available ST52 pipes. Medium concrete. 8

Innovations ESSER TX with an integrated wear indicator Due 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. Boom pipe ESSER 900 TX Double layer, hardened inner pipe XL Flange extension Hardness (acc. Rockwell) Up to 67 HRC Nominal diameter (DN) [mm] DN 2 DN 7 DN 25 Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK Wall thickness [mm] 2,0 + 2,0 2,0 +,5 2,0 + 2,0 (Inside and outside wall) 3,0 +,5 Length [mm] 00-6000 Working pressure (P) [bar] 85 Service life factor* 0 * Compared with commonly available ST52 pipes. Medium concrete. With an integrated wear indicator for ensuring maximum usage. Reducer ESSER 700 TX Compound steel, double layer, hardened inner pipe Double weld collar, hard cast inner ring type SK or OEM specific Hardness (acc. Rockwell) Up to 63 HRC Nominal diameter (DN) [mm] DN 25 / 00 DN 50 / 25 DN 25 / 2 DN 25 / 7 Wall thickness [mm] 4,0 + 4,0 (inside- and outside wall) Length [mm] > 500 Working Pressure (P) [bar] 85 Service life factor* 5 With an integrated wear indicator for ensuring maximum usage. * Compared with commonly available ST52 pipes. Medium concrete. 9

Back-end kits ESSER produces complete pump outlets for machine types of different manufacturers. Examples of different back-end kits in ESSER 900 quality Elbow 50 DN25 with extension Reducer DN50 / 25 Connection elbow 4 DN 80 Elbow 42 DN25 Elbow 90 DN50 Reducer DN 50 / 25 Swivel Elbow DN 80/50 (Version ) Swivel Elbow DN 80/50 (Version 2) Elbow 45 DN25 with extension Elbow 90 DN50 with holder Reducer DN 50 / 25 Elbow 90 DN 50 Swivel Elbow 90 DN 80 / 50 (Version ) Swivel Elbow 90 DN 80 / 50 (Version 2) 0

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. Special components Elbow with extension Rib pipes Impact- and turret elbow Multiplex elbows Special elbows Step elbows

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 4 5 5 2 3 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) 2 3 4 5 = Turret Elbow (ESSER 900) = Turret Pipe (thick walled type) = Boom Crossing (ESSER 900) = Impact Elbow 2

Performance optimisation 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 XL 3

Performance What is the performance of your pipes? 70 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 4

Wear characteristics of ESSER pipes SERVICE LIFE (Compared with commonly available ST52 pipes of the same wall thickness) 0 8 6 Service LIfe (in comparison) 4 2 0 ST52 ESSER 400 = 2 x ST52 ESSER 700 = 5 x ST52 ESSER 900 = 0 x ST52 5

ESSER-WERKE GmbH & Co. KG Zum Puddelhammer 25 5958 Warstein Germany Tel. +49 2902 896 0 Fax +49 2902 896 30 email info@esser-werke.de Home www.esser-werke.de LTB Le Teyau Bi Metal 3 Avenue de l Europe 67300 Schiltigheim France Tel. +33 3885 64 500 Fax +33 3885 64 7 E-Mail france@essertwinpipes.com Home www.essertwinpipes.com ESSER Partner EM20029 GB 5033