Things You Should Know About Vibration Concrete Pipe Machine

One of my client Antonio from the Philippines came to inspect our pipe machine yesterday, the process he producing concrete pipes currently is using the manual mold, the reason he wanted to update his concrete pipe plant is to improve the efficiency.

On our way drive back to the factory from the airport, he said that Pony, I have learned so much about all the machines on the web, but there are so many types, how can you help me to work out the best solution?

There are types of machines outside there on the market indeed, but our purpose is to improve the daily output at the meantime, get qualified pipes with high density and strength of the civil project and selling.

In order to help him to wok out the solution for her requirement, I made some points that help him to make his option.

The first machine he requested is the horizontal concrete pipe machine

spinning concrete pipe machine

The horizontal concrete pipe machine has a long history, and widely used for its simple structure and operation. With the half-dry concrete as material spinning inside the mold to form the shape.

cocnrete pipe mold

The quality of pipe made by this machine mainly based on the skill and experience of the operator, the density and strength is lower than other pipes made by other machines. The main flow of pipes during the making process is that the steel cage may go deformed during rotating of mold; and the thickness may be thicker than designed, that because the pipe forms under the spinning force and the pressure between roller and mold, if we filling moderate concrete, the pipe is not completely compacted by roller and cause the unexpected quality, if we filling more concrete, the pipe could be compacted completely, but the thickness may more than we designed.

concrete pipe mold

Invest for this machine seems lower than other equipment, but we need multiple molds for each size to meet the daily output, as the mold cannot be removed until the concrete become solid.  As experiences, machine with multiple molds, the investment may equal to the vibration pipe machines.

The other issue you may take into consideration is that if the mold and the machine are not made inaccurate dimension, the machine and mold bounce a lot during the production, that could be a potential bomb to the safety of operators.

 

After the brief introduction of the roller suspension concrete pipe machine, Antonio said that, pony, I’m outdated using the manual mold, I don’t want to invest in another traditional facility once again. Please give more introduction of the vibration machine.

The next one I introduced to Antonio is the double shifts vertical vibration concrete pipe machine.

Vertical concrete pipe machine
double shift concrete pipe machine

Using the core mandrel vibrator to generate high-frequency vibration force to form the pipe into shape. The 6000rpm vibration frequency and powerful force is strong enough to liquefy the concrete during production, and make the particles of concrete full fil space between aggregate to acquire the high density and strength, which are very important for the durable of concrete pipes. With the central control panel and electric chart for delivering pipes, only two operators could run the whole production plant.

Antonio asked me why the 6000 rpm so important? Other companies vibration frequency could up to 3000-4000, are there any differences?

This is a technical issue some of the pipe machine user may ignore when they inspect the machine. The appearance of the machine and mold is quite obvious to see and check, but the frequency, its hard to tell until you actually operate the machine.

Why exactly high frequency like 6000rpm important? The diameter of aggregate we use during the production is 5-25mm, and most of them are 15mm particles, some sand particles are even within 5mm. take the range of the diameter of aggregate and the energy decrement of vibration force into consideration, 6000rpm is the best to liquefy the concrete and get the high density and strength concrete pipes. If the vibration frequency is less than 6000rpm, it's not strong enough to liquefy the concrete, and the small particles can not full fill all the spaces of the concrete, that’s the reason why there are so many air pockets on the surface of the pipes and the water permeability is too high.

I also showed this chart to Antonio to help him compare all these concrete pipe machines.

MachinesQuality of pipeAppearance of pipeEfficiencyEco-friendlyCement consumptionEnergy consumption
Centrifugal pipe machineGoodGoodLowLowHighhigh
Horizontal pipe machineMediumMediumMediumMediumLowhigh
Manual moldGoodGoodLowMediumMediumlow
Vertical vibration machinegoodmediumhighHighlowmedium
Radial press machineMediummeidumVery highhighlowmedium

After these detailed introductions, Antonio know which machine to choose as well as we all know.

Let me know in the comment if you have any questions.

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Can your vibration machine liquefy the concrete?

Liquefaction is an appearance during the compaction of dry concrete when making concrete pipes with vibration. Liquefaction is a process that airs are expelled out of the concrete, and the aggregate of concrete is compacted together firmly.

Why is liquefaction so important for making dry-precast concrete products by vibration machine? During the liquefaction, the extra air is expelled out of the concrete, and each element of the concrete are compacted and bonded with each other in high level. The mortar produced during the process could full-fill tiny gap and space, that enables to increase the strength and the density, as well as the low-permeability.

What is liquefaction looks like? Have you ever boil waters? The air bubbles keep coming out of the surface the of water. Liquefaction of concrete looks like that. But the difference is, liquefaction is a temporary scene when most of the air is expelled out of the concrete, the air bubbles are less and less visible.

You may wonder that liquefaction is very common in wet precast, but dry concrete? Not sure.

However, liquefaction happens in dry concrete too. The vibration is matters a lot for the appearance of liquefaction. Try to adjust the vibration to high frequency (5000-6000rpm) and low amplitude (close to the self-amplitude of concrete), you will get a perfect finish concrete product.

You may not tell the differences of machines whether they can make the concrete liquefy or not. But the finished concrete product won’t lie.

The concrete product that has been fully compacted and liquefied by high-frequency vibration has a smooth surface and visible density, while the one hasn’t been produced in this way came out with a surface full of pores.

concrete product hasn't been completely compacted.

concrete pipe with pore

concrete product has been fully compacted and liquefied

smooth surface

How exactly the liquefaction looks like? Alright, I took this video, not professional, but I think it’s enough to tell.

Concrete Pipe Manufacturing Process (Vertical Vibration Machine)

DESCRIPTION OF VIBRATION CONCRETE PIPE MACHINE MANUFACTURING PROCESS

Vibration concrete pipe machine has features of highly mechanized, high density of finished pipes, good and surface, and quickly mold releasing. But you may wonder what the making process of this machine? Is it suitable for your current plant? Here are the details.

This simple chart could help you to understand how the machine process. And the process below helps to check all details.

flow chart

1. Clean the bottom ring, and the rings should be coated with mold release (you can use wasted engine oil instead of pro mold release)

bottom ring

2. Sit the out mold on to the bottom ring.

concrete pipe mold

3. Put the out mold into the working pit.

concrete pipe mold and hook

4. Start the feeding machine, and adjust the volume of concrete according to the dimension of pipes. Start the vibrator after the concrete fills about 50cm height of the mold. Vibrating while feeding concrete.

concrete pipe machine feeding

5. Feed the concrete to the top of the mold, start the hydraulic of pressing while vibrating, to form the joint.

concrete pipe joint forming

6. Lift the out mold and pipe out of the pit, delivery to the curing area.

concrete mold with pipe

7. Put the glass fiber or steel pallets on to the top of the pipe to protect the joint during the curing.

8. The pipe could self-cure with the heat of hydration of cement. And cover the pipe with plastic cover would help with the curing process.

concrete pipe curing

9. Product testing.

How To Make Dry-cast Concrete Pipe With Machine

Companies in brick manufacturing, mining, civil engineering, and contractors start involving into making precast concrete pipes for new business development. As beginners, you may wonder what kind of equipment would be appropriate for making concrete pipes. As dry casting plays a significant part in precast industry, I’m going to introduce several machines which are commonly used.

The first one, roller suspension machine.

roller suspension pipe machine

Invented by engineer Roberston and Clark in 1943 in AU, the pipe forms under the pressure of the roller and the spinning force. This machine is popular for its simple structure and low investment. But as we can’t remove the mold instantly after production, we need a huge number of molds to improve the daily output. Does this sound cost-saving? You do the math.

The second one is the vertical vibration casting machine.

vertical vibration pipe machine

Invented by Pedershaab in Denmark. As the concrete forms into shape under the high-frequency vibration force of vibrators, the strength is excellent and mold can be removed immediately after production. It can also be used to make pipes with lining and irregular concrete products.

But the frequency of vibrator and the proportion of concrete are quite matters to the quality of finished product. Equipped with robotization facilities, the machine can be operated full-automatically.

 

The third and the last I want to introduce is Radial Press Concrete Pipe Machine

Developed by McCracken in 1940, with the rollerheader rotating in high speed, it forms the concrete in high frequency. The whole production plant can be designed to three shifts or more to meet mass production. The high investment of this machine is not the only reason why people take it as a second option. As it is not appropriate to make irregular product and pipe with lining.

And the wire cage may go deform during the spinning of the header.

 

Ways to reinforce the ends of concrete jacking pipes

Due to the partial compression during the jacking process, the ends of jacking pipes are easy to go deformed laterally and become damaged. So the bearing capacity of the ends of jacking pipe should be reinforced. U shape hooping and more latitudinal reinforce wires should be used at the 200mm-300mm ends of the pipes.

The out layer of latitudinal wire should be the priority when doing the reinforcement. After the reinforcement, the span of the latitudinal wires should be 1/3-2/3 of ones on the pipe body. The reinforced u shaped hooping should be equal with the longitudinal wires of the pipe.

You may wonder how we decide the span of latitudinal wires and the length, there are five factors may help you to figure it out:

1.Jacking distance 2.geological conditions of the project 3.drivage (machinery or manually) 4.expirence and skills of the operator 5. straight jacking or curved jacking. The reinforcement should be stronger when factors above are unfavorable.

During the jacking process, the pipes forced stress not only from Poisson’s effect but from the superposition of the deviation as well. Like the picture below: the end faces of the pipe is transmitting the pressure point to point instead of end to end, so the ends of the jacking pipes are very easy to collapse and break.

The end reinforcement in long distance jacommentpe project like the diagram below, the inner and outside wall is covered by the steel ring, the thickness of steel should be 4-8mm, and length from 120-200mm.

reinforce the ends of a concrete jacking pipe

Different reinforcement for different joints of jacking pipes:
reinforce the ends of concrete jacking pipes

reinforce the ends of a concrete jacking pipe

Leave a comments if I was wrong in this article. Thanks.

What Is Concrete Pipe Making Machine And Its Function?

concrete pipe machines

The development technology has reached the highest level where one can find solutions for everything. While concrete pipe making process was going through some difficult time concrete pipe making machine came into the market and saved the time. Earlier a lot of time was consumed to make it in a customized manner but this technology made the whole manufacturing a smooth process. This machine is versatile in approach as well which can enable table vibration or central core vibration and has Falcon control.

The concrete pipe making technology avails various optional features that can be installed in this concrete pipe machine in order to improve production value. It is great for handling machine easily that are swivel automation for swivel arm and concrete feeder which also includes vibrator and swivel arm, pendant switch for operation of concrete feeders, hydraulic pressing/rocking function, stationary control panel, R4 headers, lifting hole equipment, top ring system and much more. This vertical cast concrete pipe machine is a manually operated machine and thus, it can manufacture high-quality box culverts, concrete pipe, and complete manhole systems.

Designed with the state-of-the-art components, it is suitable for all types of concrete pipes of different shapes and sizes. Concrete pipe making machine can also make circular and non-circular pipe with “bell” or in-wall joint, reinforced and non-reinforced pipe, lined pipe, box culverts, jacking pipe, manhole risers, base sections, cones and cover slabs. It can enable versatile productions of pipe, culverts and complete manhole systems of up to 1500 mm in diameter for circular units and up to 1500 x 1500 mm for square units. Though the capacity of this machine depends on the kind of concrete pipe being produced, with the help of this machine all concrete pipes and manhole systems are manufactured with an inner lining of PVC, PE or GRP with special mold attachments.

Bothered by air pockets on the surface of concrete pipes? here is solution

Yesterday, one of my friends Chandrakant told me he is upsetting by the air pockets (or more) on the surface of the concrete, like pictures below.

Adjust the vibrator to high frequencies like 6000rpm instead of 4000rpm, and low amplitude instead of high, let's see what happened.

You may try when your users are critical to the surface of pipes.