Why Integrated Batching and Pumping Can Simplify Concrete Placement

[edit] Introduction

Concrete placement can require coordination between concrete production, delivery, pumping and the final placement point. Conventional arrangements may use separate equipment for batching and mixing and for pumping, requiring the different elements to be positioned and operated as a coordinated system.

Integrated batching and pumping equipment combines concrete production and pumping functions within a single equipment system. This can reduce the number of separate equipment interfaces and material transfer stages, particularly on projects where space, access or mobility are significant considerations.

[edit] How integrated batching and pumping works

A conventional concrete production and placement arrangement separates mixing from pumping. A batching plant produces concrete, which is then transferred to a concrete pump, often using mixer trucks or other transport arrangements. The pump subsequently conveys the concrete through a pipeline to the placement point.

An integrated system combines batching, mixing and pumping within the same equipment package. Aggregates, cement, water and any required admixtures are proportioned and mixed before the resulting concrete is transferred directly to the pumping system.

The precise configuration varies between equipment types. Some systems are designed for mobile use and relatively small production volumes, while larger projects may require separate batching, transport and pumping equipment.

[edit] Reduced equipment coordination

Where batching and pumping are provided by separate machines, their production and pumping rates need to be coordinated. Interruptions in either process can affect the continuity of concrete placement. An integrated system can simplify this relationship because batching, mixing and pumping are designed to operate as parts of the same process.

This does not eliminate the need for site coordination. Aggregate and cement supplies, water, admixtures, power, pipeline arrangements and the operation of the placement area still need to be managed.

[edit] Reduced material transfer

An integrated system can reduce the number of transfers between concrete production and placement. Concrete can pass from the mixer directly into the pumping mechanism rather than being discharged into a separate transport vehicle before being loaded into a pump.

Reducing transfer stages can be particularly useful where site space is restricted or where vehicle access to the placement area is difficult. It can also reduce the amount of equipment required within the immediate working area.

[edit] Applications

Integrated batching and pumping equipment may be suitable where concrete needs to be produced close to the point of placement and where a conventional batching plant, mixer trucks and separate pump would be difficult to accommodate.

Potential applications include:

• infrastructure construction;
• bridge and tunnel works;
• foundations;
• road and rural infrastructure;
• remote construction sites;
• projects with restricted equipment access; and
• small and medium-sized concrete works.

The suitability of an integrated system depends on the required concrete volume, mix characteristics, pumping distance, site conditions and duration of the work. Large projects requiring high and continuous concrete output may continue to use a centralised batching plant with separate transport and pumping equipment.

[edit] Factors to consider when selecting equipment

The equipment configuration should be selected according to the requirements of the concrete production and placement process rather than simply the nominal output of the plant.

[edit] Production and pumping capacity

The required concrete output should be established before selecting equipment. Batching and pumping capacities need to be considered together, since the overall placement rate is constrained by the capacity and operating conditions of the complete system.

Actual output can be affected by material loading, batching and mixing cycles, concrete mix characteristics, pumping conditions, equipment availability and interruptions to the placement process. Nominal production figures should therefore not be treated as guaranteed site output.

[edit] Pumping distance and elevation

The required horizontal and vertical pumping distances should be established as part of the equipment selection process. Pipeline length, changes in elevation, bends, pipe diameter and the characteristics of the concrete mix all influence pumping requirements.

The concrete mix must also be suitable for pumping. Aggregate grading, workability, cementitious content and admixtures can affect pumpability and the risk of blockages or interruptions.

[edit] Site conditions and access

The available space for positioning the equipment, loading aggregates, supplying water and materials, and installing the delivery pipeline should be assessed before mobilisation. Ground conditions and access routes also need to be adequate for the equipment and for any vehicles required to supply materials.

Mobile integrated systems can provide greater flexibility where equipment needs to be relocated between work areas. However, mobility does not remove the need for suitable access, ground preparation and safe operation.

[edit] Power and services

The power requirements of the batching, mixing and pumping equipment should be established before installation. Depending on the equipment, an external electrical supply or an integrated power source may be required.

Water supply, aggregate storage and the handling of cement and admixtures must also be considered. The arrangement should allow materials to be supplied at a rate consistent with the required concrete production.

[edit] Comparison with conventional arrangements

Integrated batching and pumping is not necessarily a replacement for a conventional batching plant and separate concrete pump. The two approaches address different project requirements.

A conventional arrangement can provide greater flexibility in the scale and location of concrete production and may be appropriate where large volumes of concrete are required. Separate equipment can also allow batching and pumping operations to be independently sized or replaced.

An integrated system can reduce the equipment footprint and simplify the movement of concrete between production and placement. This may be advantageous where the concrete needs to be produced close to the work area or where access limits the use of multiple machines.

The appropriate arrangement therefore depends on production volume, site layout, access, pumping requirements, concrete mix design and the duration and scale of the work.

[edit] Related articles on Designing Buildings

• Concrete batching plants
• Types of Concrete Batching Plants
• Mini concrete pumps
• What to Look for in a Concrete Batching Plant
• Blocked concrete delivery pumps.
• Cast-in-place concrete.
• Concrete.
• Concreting plant.
• Technical Engineer's Perspective: Performance of Concrete Trailer Pumps in High-Rise Buildings
• How to Choose the Right Concrete Batching Plant Solution for Different Concrete Grades