It involves the use of a concrete mixture, which is supplied using a special pump to the pouring site. A concrete pump is a very expensive machine, and therefore its use is beneficial only on large-scale construction sites. What to do with private monolithic construction? The way out of this situation is a homemade concrete pump.
You will learn how to make a concrete pump with your own hands and what you will need for this.
Piston
There are two types: rotary and piston. There is no need to examine the rotary device. Firstly, this does not make sense, since this will talk about how to make a piston concrete pump. And secondly, the rotary pump is complex in its design and disassembling its design will take a lot of time.
The piston concrete pump consists of three large parts, each of which performs its own function. These details are:
- piston;
- cylinder;
- drive unit.
Each of these parts consists of smaller components, which will be discussed below.
The cylinder is a container in which two check valves are built in. They are responsible for sucking the concrete mixture from the receiver and pumping it into the concrete pipeline. This process is possible thanks to the work of the piston.
Now the relationship between the operation of the piston and the cylinder will be examined in more detail. When the concrete pump starts, the piston begins to work (move). Making the first movement, the piston creates a discharge in the cylinder, which allows the concrete mixture to enter the receiver. The piston continues to move and, having reached the end point of its movement, begins to return to its original position. This process creates pressure that forces the mixture into the concrete pipe, which carries the concrete to the pouring site.
Industrial ones use two pistons for their work, which increases their power and complicates the technological parameters. This state of affairs is acceptable for large-scale construction projects, where the high cost of a two-piston powerful concrete pump will pay off in the process.
In relation to private monolithic construction, this approach is unacceptable. As already mentioned, buying is an expensive pleasure. Therefore, the only option is to manufacture homemade pump with one piston. You can, of course, try to make a two-piston concrete pump. However, this is pointless, since, firstly, these works will be technically complex, and secondly, for private monolithic construction, a single-piston is quite sufficient.
Manufacturing process
Any undertaking, any business will be successful only if it is planned competently and thoughtfully. This is the law, and you can't argue with it. Therefore, before you start working on creating a concrete pump, draw up detailed plan. In it, calculate the monetary and time costs of your venture. Think about where you will get the material and parts, how the diagram and drawing will be created.
Dimensional drawing
After you have thought through all the issues related to the work, you can begin to draw up a document such as a drawing. An engineering education that allows you to create drawings and diagrams of such units will be a huge advantage for you. If you do not have such education and skills, then you should turn to those who have them.
Well, or look for a drawing on the Internet. Just don’t try to grab the first diagram you come across and start working on it. The best option it will be if you look for a drawing on construction forums, where you can ask questions to those who have already made concrete pumps with their own hands.
Cylinder and piston
As mentioned above, the main elements of a piston concrete pump are the cylinder and the piston itself. When making them, you need to be especially careful, because the operation of the concrete pump itself depends on these parts and their operation.
Here are some mandatory requirements for a concrete pump cylinder and piston. The cylinder diameter should not be less than 400 millimeters. Regarding the piston, it should be noted that its working stroke should not be less than half a meter. Such values were introduced for a reason.
The fact is that a concrete pump with a small cylinder and a small piston stroke is more susceptible to wear. This concrete pump makes large quantity cycles for pumping concrete than a similar unit would do, but with a larger piston stroke and a larger cylinder diameter.
To reduce wear during production check valves– parts that are most subject to loads in a concrete pump – use high-strength material. This material is alloy steel. It is she who is able to withstand heavy loads.
To manufacture these main parts of the future concrete pump you will need:
- Bulgarian;
- emery wheel;
- screwdriver;
- kit wrenches;
- lathe (there are small models that are perfect for your idea).
Automatic drive
Of course, your concrete pump will not work without a drive. When thinking about which drive to choose, you need to remember simplicity and economy. The most affordable, economical and easiest to install is the electromechanical drive. It is head and shoulders above the second most commonly used hydraulic drive.
Your concrete pump will be driven by an asynchronous electric motor, which is powered from three phases. Next you will need special device– a gearbox that reduces the gear ratio, and a mechanism that converts the rotational movement of the engine into the translational movement of the piston. In order to set the piston in motion, the converting mechanism and the piston are connected by a pin.
Here is a list of what you will definitely need in the process of attaching the drive to the concrete pump:
- electric motor, gearbox and kingpin (in fact, installation is impossible without them);
- set of wrenches;
- screwdriver and screwdrivers;
- insulating tape;
- copper wires;
- electric indicator
Exploitation
Once your concrete pump is assembled, you need to test it. This is mandatory, since only in this way is it possible to ensure the safe and correct operation of the device you have assembled. Under no circumstances should you try to check for Idling.
Before turning on the concrete pump for the first time, you should pour concrete mixture into it. For the first time, for a test run, it may be concrete with a high water content. You can also add machine oil there, which will prepare the concrete pump for further operation. If everything went well, then you can be proud of yourself. Just remember to disassemble and clean the unit after each use.
Construction work in the private sector is carried out constantly and at a fairly rapid pace. Of course, haste has not yet brought full benefits to anyone, but given the growing cost of materials and work, you want to speed up the process, and this can only be achieved with auxiliary equipment. If we're talking about about filling monolithic foundations, formworks or floors, then practically no alternative is to use devices for feeding ready mixture V work area. To save even more, you can not resort to renting, but make a concrete pump yourself, based on existing manuals. Let’s try to figure out further what this technique is, what it consists of, and how to make it work.
Pouring foundations or floors involves creating a homogeneous mass. Doing this manually with large volumes and areas is almost impossible. This approach leads to the formation of focal structures: a part has already begun to harden, and more fresh concrete is gradually added to it. Obviously, this structural element will not have uniform characteristics; its shrinkage and shrinkage in different points will go according to its own script.
You can speed up the pouring process, and therefore bring the structure as close as possible to the required one, by using mixers in combination with concrete pumps. The former ensure continuous preparation of the mixture, and the latter ensure its supply to the working area. The main difference between such superchargers and conventional water pumps is the structure of the moving medium. Concrete is a more viscous, thick (paste-like) material, which forces the use of slightly different principles and technologies for its transportation. Products existing on the market are divided into two large groups: rotary and piston.
1. Rotary concrete pumps.
These are transport mechanisms that use flexible suction and pressure hoses (positions 1, 5 and 9 in the illustration).
Like in any car of this type? here there is a main chamber where the sleeves and a rotating eccentric rotor 4 are located. It has rubber-coated rollers 3, which during rotation compress sections of the suction and intermediate lines, pushing the mixture into the supply line. Such machines have a volumetric capacity of up to 70 m3/hour, with a horizontal and vertical head of 300 and 70 m, respectively. Due to the high complexity of the design and manufacturing technology of individual components, it is unlikely to be possible to assemble a concrete pump of this type on your own and focus attention on it doesn't make sense.
2. Piston concrete pumps.
These are more productive (up to 200 m3/hour) and widespread machines. Unlike the previous type, here driving force is not a rotor with rollers, but a piston that pushes a certain dose of concrete into the supply line. Industrial designs use a scheme with two parallel pistons, which are alternately connected to the concrete pipeline through a C- or S-shaped gate.
During operation of the concrete pump, concrete from the hopper is supplied into the chamber with the gate and sucked into one of the cylinders that are open at that moment. After filling, the gate is connected to it and the piston pushes the concrete into the supply pipeline. At the same time, in the adjacent block the working unit moves back and material is collected.
Periodic switching of the feed cylinders allows you to save on their size (primarily length), ensuring continuous supply in accordance with the instructions.
Assembling such a concrete pump with your own hands is not as complicated a procedure as it might seem at first glance. Moreover, if we take into account the relatively small volumes of work in the private sector, the scheme can be significantly simplified by using only one pressure cylinder. This will reduce the number of upcoming actions and their overall cost.
Where to begin? Step-by-step instruction
Any technically complex undertaking can be implemented in practice, subject to a competent assessment of the situation and correct calculations. Needs to be analyzed existing technologies, select an acceptable scheme for the manufacture and assembly of individual components and assemblies for working with concrete, find suitable materials And finished parts. You also need to develop drawings according to which the piston, cylinder, and body will be created. It would be a good idea to prepare operating instructions for the concrete pump.
Preparation project documentation is also carried out independently, especially if you have specialized education and understanding of the basic principles of development. If this does not work out, then you need to seek help or advice from professionals or search for information on the Internet: on specialized forums you can easily find ready-made drawings and manuals for assembling and operating units for working with concrete.
How to make the main elements?
The accuracy of the functioning of the concrete pump depends on how optimally the parameters of its main components were selected. The diameter of the master cylinder is selected based on the range of 42–400 mm. The piston stroke will be recommended to be within the range of 500–900 mm to ensure a sufficient volume of concrete unloading.
It is recommended to make check valves used in the design from alloyed, preferably stainless steel, which will significantly extend their service life in direct contact with concrete. Parts that have the shape of a shaft are turned from blanks to lathe. The required size accuracy is adjusted by grinding. It should be noted that when docking, the deviation should be within ±0.1 mm.
The main components of the concrete pump are assembled using screwdrivers and wrenches. The finished pump is connected to a drive (hydraulic, mechanical). In the first case, a hydraulic system is used, which guarantees greater travel and durability. The second option uses an intermediate gearbox, as well as a crank pair. In this case, it is impossible to ensure a sufficiently long stroke, which means that the frequency of movements increases, which inevitably affects the service life.
The average cost of manufacturing such a concrete pump is in the range of 50,000 - 60,000 rubles, but depending on the materials and components, as well as the economic situation affecting pricing, this figure may differ (usually upward).
Correct use of equipment
The first stage, the starting point in the process of working with a concrete pump, is its start-up and running-in - sea trials. It is strictly forbidden to perform a test run in idle mode on a concrete pump that is not filled with material. Used as a working mixture machine oil, concrete, which is diluted with sufficient water.
Each operational cycle must be completed with scheduled disassembly and cleaning in accordance with the instructions. This should be done because it will be extremely difficult to chip away at hardened concrete, and constant contact with the working surfaces can lead to their premature wear.
A homemade concrete pump is a useful unit for working with concrete in monolithic construction, which allows you to speed up the process of pouring the mixture and save on the services of private companies. But its production must be thoughtful so that the money and time spent on development and assembly can be guaranteed to pay off.
When used in construction monolithic concrete there is a need to use small-scale mechanization tools. One of them is a concrete mix pump. This unit has a high cost and purchasing or renting it leads to significant financial costs. To reduce costs, you can try making a concrete pump with your own hands. short time. How to do this? The answer to this question is given below. First we need to consider existing types concrete pumps:
- stationary unit – used for large volumes construction work, carried out far from megacities in difficult climatic conditions;
- Automotive concrete pumps are mobile units used for small-scale construction in urban environments if they are located nearby. construction site concrete plant.
For self-made The second option suits us. By internal structure they are divided into the following categories:
- piston pumps have a fairly simple design. Suitable for DIY production;
- rotary - difficult to manufacture due to the presence of parts in the design high precision.
So, let's make a piston concrete pump. It consists of several parts:
- piston;
- cylinder;
- drive mechanism.
The concrete mixture is drawn in and pumped into the pipes using two check valves installed in the body of the cylinder. The movement of concrete is carried out using a piston, which creates a vacuum as it moves along the cylinder. When the extreme position is reached, the piston creates pressure during the reverse stroke, and the concrete mixture enters the transport pipes, and from there to the pouring site. An electric vibrator is used to compact the mixture.
The samples of such pumps manufactured by companies use two-piston circuits to ensure smooth running and shock-free operation of the unit.
In addition to the main parts listed above, the pump also contains other smaller components. For self-production, we will accept the design with one piston as a cheaper and less complex option.
Drawing up a drawing
To carry out your plans correctly, you need to start by creating a work plan and think through the technology for manufacturing a concrete pump in detail. The first step is a drawing of the unit. To make things easier, we provide approximate diagram pump design and parts (Fig. 1).
The above drawing can be used directly for its intended purpose, but if you are not satisfied with something in it, you can make changes to it or replace it with another. The drawing is transferred to whatman paper with all dimensions and a specification is added indicating the materials used.
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Manufacturing of concrete pump cylinder and piston
Figure 1. Dimensional drawing of the pump.
These are the main design parts, and the following requirements are imposed on them:
- to reduce wear on unit parts, the diameter of the working cylinder is selected to be at least 380-420 millimeters;
- the piston stroke is selected within 0.6-0.9 meters;
- check valves that are heavily influenced by the concrete mixture are necessarily made of a material such as alloy steel.
Round parts are made on a lathe. Then, using grinding and emery wheels, they are cleaned and brought to required sizes. The body can be made from sheet iron. The valves are assembled using a screwdriver, and the entire structure is assembled using wrenches. By connecting the assembled concrete pump to the drive, the entire unit can be installed on a single-axle trailer.
The drive to which the pump is connected can be of different types:
- electromechanical;
- hydraulic.
The first option is suitable for our purposes. The drive drawing is shown in Fig. 2.
It operates from three-phase asynchronous electric motor and is connected to the piston rod through a reduction gearbox and a conversion mechanism, which converts the circular movements of the engine shaft into translational movement (forward - backward) of the piston rod. The drive is installed in the following order:
- an electric motor with a starter is installed on the base (trailer with a concrete pump installed on it);
- a gearbox is attached to its shaft and secured with bolts;
- assemble the converter mechanism and connect it to the piston and the output roller of the reduction gearbox;
- The power cable is connected to the electric motor.
Screw pump, or as it is otherwise called, screw - unit high efficiency, functional characteristics which does not depend on the positioning of the housing installation and the quality/properties of the liquid that the device pumps. Simply put, screw pumps can handle water flows that are extremely saturated with insoluble and soluble particles. Moreover, they can be mounted vertically, horizontally, or changing position from time to time.
Using this unit, it is possible to organize pumping of flows of any composition: from discharged steam to medium-viscous suspension, and in any case, the screw design solves all the tasks assigned to it. Due to its wide capabilities, the equipment is most often used as a pressure generator:
- In systems autonomous water supply , assembled with your own hands or through the services of professionals. It is noteworthy that the pump works not only in perfectly clean wells and boreholes, but also in sandy mines.
Important! Submersible screw pumps have performed very well in wells with a high content of sand inclusions, providing sufficient pressure at serious mine depths.
- In systems for pumping and pumping liquid compositions/mixtures. Screw pumps are found on construction sites, drainage structures, main pipelines, and production units. The breadth of application is explained by the unique capabilities of the pumps - they pump any substance: from steam to liquid concrete.
- In systems for dosing liquid flows. In processes, the screw serves as both a generating and dosing mechanism. At the same time, the accuracy of the portions remains unchanged, regardless of the installation position of the unit.
Convenience lies in the fact that trouble-free screw pump easy and simple to install with your own hands. At the same time, it does not require constant inspection and lasts quite a long time.
Features and nuances of operating screw group pumps
The wide range of application of the mechanism, a convenient and practical way of generating pressure force, endow screw pumps with the following operational features:
- Ease of maintenance, maintainability. It is easy to dismantle the part field conditions with your own hands, having only a minimal set of tools. For example, the bearing is easy to remove, and replacing the seal does not require removing the pump. Any node is practically “in sight” and therefore getting to it will not be a problem.
- Case Features pump design equipped with a unique suction pipe, the design of which minimizes the formation of silt deposits that complicate the process of pumping flows. In this case, the pipe can be positioned not only along the center (along the axis), but also perpendicularly, at an angle of 90 degrees.
- Main mechanism of the unit produced by casting followed by processing on high-precision machines. Therefore, the devices have an extremely low noise threshold, operate without vibration and have a very long service life.
Review of typical equipment models
The functionality of the device is provided by a screw-type shaft, which creates a vacuum at the suction end hole by pushing a small volume of liquid towards the discharge pipe. Having undergone a lot of improvements and changes, screw pumps have become universal devices that generate the required level of pressure in the pipeline. Today the following representatives of the product line are popular:
- Aquarius . Compact unit up to 10 cm in diameter, productivity from 2000 l/hour. Installation is extremely simple, use is recommended in wells and wells. Water is pumped from the mine by hanging the device on a cable, but from an open reservoir Aquarius pumps water in any position. Inexpensive and practical equipment can be quickly installed and dismantled with your own hands.
- Screw type barrel pump- This is a structure used for pumping water from various reservoirs. Models are offered by many manufacturers, but all devices have the following characteristics: modest size and low power, the manufacture of devices is allowed only from the most durable materials, non-corrosion and resistant to active/aggressive environments.
A barrel screw pump is a unit with specific characteristics that can be used to pump not only water, but also alkalis and acids.
- Belamos are deep-type units. Equipped with high-quality components and well-assembled devices, they are famous for their reliability and ability to operate for a long time without interruptions for the “rest” of the motor part. At the same time, there is protection against dry running, overheating, and other breakdowns.
Important! Belamos pumps are especially good for working with deep mines and quicksand. Installation can be done with your own hands in just a few minutes, and the high power will allow you to quickly cope with pumping out dirty flows. In this case, there is not the slightest threat of sinking the device, since the installation is carried out on the surface.
- UnipumpECOVINT is a pump for working with wells and wells with minimal debit of the aquifer. The small size and high throughput of the equipment will come in handy in summer cottages. The pump easily fits into a small diameter casing pipe and provides water supply for a family of 2-4 people. Moreover, even a beginner in plumbing can install the pump with his own hands.
Important! Any screw-type pump does not generate vibration movements, so bottom sediment does not rise up, spoiling the purity of the supplied flow. The design is ideal for solving the provision of constant water pressure in autonomous system water supply, sewerage.
To make a concrete pump with your own hands, it is not enough to have money for necessary details– this requires patience, certain skills and ability.
The purpose of the concrete pump is to receive freshly prepared mixture from concrete mixer trucks and supply it to the work area.
Of course, self-made construction equipment will look different from the factory model, but this factor will not affect its functioning in any way.
What types of concrete pump designs exist?
It is worth making a concrete pump yourself if large-scale construction is planned, otherwise it is more profitable to rent it.
Regarding this type of purchase construction equipment, then we must immediately say that we are talking about expensive equipment here.
Currently on construction sites Two types of concrete pumps can be used: pistonless and piston.
The design of the first unit involves supplying the concrete mixture using rollers equipped with the rotor housing - during rotation, the rollers exert pressure on the supply hose, resulting in the release of concrete.
Assembling a rotary-displacement type structure with your own hands is more difficult than making a piston model yourself.
Reciprocating equipment drawings include three main parts, each necessary to perform a specific function:
- piston - makes the cylinder work;
- cylinder - responsible for taking concrete from the bunker and pumping it;
- drive – electromechanical or hydraulic can be used.
In this article we will talk about assembling a single-piston pump with your own hands, which first began to be used in Germany at the beginning of the 20th century.
Double piston type concrete pumps have complex design, and therefore are more expensive - there is no point in considering making them yourself.
It should be noted that the operation of 2-piston equipment can be carried out through the operation of a diesel or electric engine; their use allows hydraulic energy to be converted into mechanical energy.
The piston system operates via a hydraulic drive cylinder in antiphase.
The cylinder of the unit is equipped with two check valves, which are activated by the piston.
The operating principle of construction equipment can be understood by considering the interaction of the cylinder and the piston system.
When the concrete pump is turned on, the piston begins its action - first, the part forms a discharge inside the cylinder, as a result of which the construction mixture enters the hopper.
The piston reaches the designated point and returns to its original position, due to this pressure is created, which contributes to the release of the mixture into the concrete pipeline, after which the concrete mixture is already supplied to the pouring point.
How to make a simple concrete pump?
As already mentioned, modern concrete pumps have two pistons, which increases the power of construction equipment and technical characteristics.
It is advisable to use such designs on large-scale construction sites, because only in this way will it be possible to recoup their cost.
It turns out that in small-sized individual construction, even renting them may turn out to be unprofitable.
IN in this case It is worth considering the possibility of making a single-piston unit with your own hands.
As a rule, each project begins with planning, which allows us to obtain a high-quality final result.
Therefore, before starting to assemble the structure for supplying concrete, you need to draw up a plan with your own hands, which should include points about monetary costs, purchase required material and parts, as well as an assembly diagram.
The diagram of the future pump is formed after the action plan is ready. In the process of drawing up drawings, it would not be a bad idea to ask for help from a specialist with an engineering education.
It was said above that the main parts of a concrete pump are the cylinder and the piston, therefore the correctness and duration of operation of the concrete pump depends on the quality of their manufacture.
When assembling the unit, two main points need to be taken into account:
- the cylinder must have a diameter of at least 400 mm;
- the piston must have a stroke of at least 500 mm.
The indicated values are due to the following factor. If the unit is equipped with a cylinder with a smaller diameter, and piston system operate with a smaller stroke than specified, then such a design is subject to rapid wear.
In this case, the machine performs more cycles to help pump a certain volume construction mixture than similar equipment with the above cylinder diameter and stroke size.
To increase the service life of the concrete pump and reduce the wear rate of its parts, it is recommended to use high-strength steel for the manufacture of check valves, which can withstand heavy loads.
Key points for assembling a concrete pump
In the process of manufacturing the working parts of a concrete pump with one piston, you will need a set of wrenches, an angular Grinder, emery wheel and screwdriver.
It is worth keeping in mind that you may also need a lathe to make some elements, without which it will not be possible to assemble the structure.
Round small parts are turned on a lathe, which are then cleaned and taken to the desired parameters.
Sheet iron is used to make the concrete pump housing.
And, of course, the concrete pump cannot be put into operation without a drive, but when choosing a drive system, you need to take into account its features.
The drive for this type of construction equipment must be simple and economical.
To start the concrete pump you will need:
- asynchronous electric motor fed from three phases;
- gearbox – reducing the gear ratio;
- reciprocating piston converter.
Important! In order for the piston to start moving, it must be combined with the converter using a pin.
Further assembly of the concrete pump is simple. First, by welding metal profiles The frame is made, then the concrete pump elements are attached to it according to the diagram, and an electric motor with a switch is connected.
Using bolts, the gearbox is fixed to the electric motor shaft, the converter is assembled and mounted, after which all that remains is to connect the cable to the electric motor.
Once the concrete pump assembly is completed, it is recommended that it be tested to ensure that the unit is functioning correctly.
At the same time, it is strictly not recommended to carry out the test at idle speed. Therefore, before turning on the concrete pump, you need to fill its receiver concrete mixture. For a test run, the concrete may have a very liquid consistency.
Experts advise adding a little motor oil to the first mixture, which will at the same time not only test the performance of the unit, but also prepare it for subsequent operation.
If the test was successful, then the concrete pump will only need to be disassembled and cleaned, which will need to be done after each use.
You can add a mobile function to the unit by placing it on a single-axle trailer, which will allow it to be moved around the construction site or sent to other construction sites.
