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TWIN-LAYER PIPES

Service Manual – EM070190 Page 1

A custom made TWIN-LAYER PIPES
pipe system for your
concrete pump Page 2

Service Manual – EM070190

TWIN-LAYER PIPES

The Metric 148 mm – 5 ½“ delivery system

Even though movement and flexing of the pipes of up to 2 deg. is possible,
the couplings will stay tight without leakage.

Service Manual – EM070190 Page 3

TWIN-LAYER PIPES

The problem of Metric delivery lines,
with standard mild steel pipes.

Short service life of standard Uneven wear at inlet / outlet flanges
mild steel pipes. caused by the turbulences at the gap
Rock is harder than steel. and offset between the two pipes.

Service Manual – EM070190 Page 4

TWIN-LAYER PIPES
Specific areas of high wear require special components

Wear at the outlet of the reducer. Wear at pivot points. Elbows installed at the end
of the boom in a descending
Service Manual – EM070190 position are destroyed by
impact wear.

Page 5

TWIN-LAYER PIPES

Which essential qualities exist for Metric delivery lines?

• ST 52

Pipes made of standard steel combined with cast elbows.
Easy to weld, only short service life, uneven wear.

• Pipes with a modified chemistry of the steel

Cheaper pipes made of ST 37 as well, as more expensive tempered pipes for example,
do not improve the cost situation.

• Single layer hardened pipes

Easy to weld, measuring of the wall thickness is possible from the outside.
Service life and costs are 2-3 times higher than ST 52, which does not really
show an improvement in cost savings.

Service Manual – EM070190 Page 6

TWIN-LAYER PIPES

Which essential qualities exist for Metric delivery lines?

• Twin-Layer Pipes (ESSER TWIN PIPE 660)

Approx. 4-6 times more service life and only 2-3 times more expensive
than mild steel ST 52.
The wear factor has been substantially improved in comparison to ST 52 pipe.
The welding of these pipes is only possible if special cooling is available.
The wear is still not exactly even.

• Twin-Layer Pipes with Twin Cast Inserts (ESSER TWIN CAST 900)

With a special reinforcement and Twin Cast Elbows the most economical solution.
Approx. 8-10 times more service life and only 4 times more expensive than ST 52.
Even wear within the entire delivery line.

Service Manual – EM070190 Page 7

TWIN-LAYER PIPES

Boom Pipe Systems

ESSER TWIN PIPE 660 ESSER PIPE TWIN CAST 900
DN 125 – 4.8“ (2.5+2.0 mm) DN 125 – 4.8“ (2.5+2.0 mm)

• Service life 4-6 times • Hardened inner layer with a
compared to ST 52 plus. hardness up to 67 HRC.

• Hardness up to 63 HRC. • Service life 8-10 times compared
to ST 52 plus.

Depending on the design and the boom size wall thicknesses of 2.0+2.0 mm, 2.5+1.5 mm and 2.0+1.5 mm are
available, as well as an inner diameter of 130 mm (5.12“), 117 mm (4.6“), 112 mm (4.4“), 100 mm (3.94“).

Service Manual – EM070190 Page 8

TWIN-LAYER PIPES

Deck Pipes and preferred Pipe Systems of up to 85 bar (1233psi) for
stationary concrete pumps

ESSER TWIN PIPE 660 ESSER PIPE TWIN CAST 900
DN 125 4.8“ (5.6+3.0 mm) DN 125 – 4.8“ (5.6+3.0 mm)

• Service life of 4-6 times • Hardened inner layer with a
compared to ST 52 plus. hardness up to 67 HRC.

• Hardness up to 63 HRC. • Service life 8-10 times compared
to ST 52 plus.

Service Manual – EM070190 Page 9

TWIN-LAYER PIPES

Areas exposed to extreme wear
on pipe systems of concrete pumps

Area #1 + #2 Pivot Points
Area #3
First Deck Elbow
Area #4 after Reducer
Area #5
Area #6 Turret Elbow
Area #7
Impact Elbow

Reducer

Boom Cross-Over-Pipe
with Elbows of less than
90 deg. angle.

Service Manual – EM070190 Page 10

TWIN-LAYER PIPES

Area #1 and #2 - Elbows at pivot points

Highest wear between the outlet of the first and the inlet of the second elbow.

The ESSER TWIN CAST 900 Elbows
with optimized Big Mouth flanges.

ESSER TWIN CAST 900
Elbow DN 125 - 4.8“ x 90°

• TWIN CAST inner layer
wall thickness 7.0 mm.

• Hardness up to 67 HRC.
• Ultra wear resistant

Big Mouth TWIN CAST flange
at the inlet and outlet end.

Service Manual – EM070190 Page 11

TWIN-LAYER PIPES

Area #3 – First Deck Elbow after Reducer

Due to the velocity and turbulence of the concrete and the location of the first elbow after
the reducer, a special extremely wear resistant TWIN CAST Elbow is needed.

ESSER TWIN CAST 900 Page 12
Elbow DN 125 - 4.8“
• Twin Cast inner layer

wall thickness 7.0 mm.
• Hardness up to 67 HRC.
• Ultra wear resistant

Big Mouth TWIN CAST flange
at the inlet and outlet end.

Service Manual – EM070190

TWIN-LAYER PIPES

Area #4 – Turret Elbow

Due to the velocity of the concrete and the frequent stroke changes of the concrete pump,
an impact situation is created within the 90 degree bottom elbow of the turret.

ESSER TWIN CAST 900 Page 13
Turret Elbow DN 125 - 4.8“ x 90°
• Ultra wear-resistant
• TWIN CAST Big Mouth inlet / outlet

flanges.
• Service life 8-10 times compared

to common cast elbows.

Service Manual – EM070190

TWIN-LAYER PIPES

Area #5 – Impact Elbow

The IMPACT ELBOW is the next to last elbow at the end of the boom and exposed to
extremely high wear. In most pumping applications the descending
position of the last boom section allows the concrete to fall into the
next to last elbow causing ultra high impact wear.

ESSER TWIN CAST 900
Impact Elbow DN 125 - 4.8“ x 90°

• The Esser TWIN CAST 900 impact elbow is
designed with a 12 mm ultra wear and impact
resistant cast inner liner.

• Hardness up to 67 HRC.
• Areas exposed to extreme wear are protected

by the Big Mouth TWIN CAST flanges.
• The impact elbow delivers 8-10 times longer

service life than a conventional cast iron elbow.

Service Manual – EM070190 Page 14

TWIN-LAYER PIPES

Area #6 – Reducer

Reducers create a higher velocity towards the outlet end and cause an increase of pressure
in the concrete flow. Especially the ESSER 900 Reducers have been improved
at the critical areas.

ESSER TWIN Reducers 780
DN 150-125 (5.9“-4.8“)

• Highly wear resistant wear rings in
the inlet flange.

• Manufactured from laminated steel.
• Hardness up to 63 HRC.
• Wall thickness 4.0+4.0 mm

ESSER TWIN CAST 900 Reducers
DN 150-125 (5.9“-4.8“)

• Pressure resistant outer shell.
• Ultra wear resistant TWIN CAST

inner layer.
• Special TWIN CAST wear rings at

inlet and outlet flanges.
• Hardness up to 67 HRC.

Service Manual – EM070190 Page 15

TWIN-LAYER PIPES
Area #7 - Boom Cross Over Pipe and Elbows TWIN CAST 900

Standard New improved
ESSER TWIN CAST 900 ESSER TWIN CAST 900
Big Mouth XL
The specifics of long booms in most cases
require Cross-Over-Pipes that are fixed
between two 45 deg. (or less) Elbows.
The velocity, turbulence and diversion of
the concrete causes extreme wear in the
outlet Elbow of the Cross-Over-Pipe
assembly. The improved design with Big
Mouth XL flanges will increase service
life by approx. 50%.

Please note:
For improved service
life pipes and elbows

should be rotated
according to the
service information

Service Manual – EM070190 Page 16

TWIN-LAYER PIPES

Area #1 + #2 Areas exposed to extreme wear
Area #3 on pipe systems of C-Valve concrete pumps
Area #4
Area #5 Pivot Points
Area #6
Area #7 First Deck Elbow
after Reducer
Area #8
Turret Elbow
Service Manual – EM070190
Impact Elbow

Reducer (short, only
on C-Valve machines)

Boom Cross Over Pipe
with Elbows of less than
90 deg. angle.

Pressure Pipe (only
on C-Valve machines)

Page 17

TWIN-LAYER PIPES

Area #6 – Reducer on C-Valve Machines

Reducers create a higher velocity towards the outlet end and cause an increase of pressure
in the concrete flow. Especially the ESSER 900 Reducers have been improved
at the critical areas.

ESSER TWIN Reducer 800
DN 137-125 (5.4“-4.8“)

• Highly wear resistant cast insert in the
inlet flange.

• Manufactured from laminated steel.
• Hardness up to 63 HRC.
• Wall thickness 4.0+4.0 mm.

ESSER TWIN CAST 900 Reducer
DN 137-125 (5.4“-4.8“)

• Pressure resistant outer shell.
• Ultra wear resistant TWIN CAST

inner layer.
• Special TWIN CAST wear rings at

inlet and outlet flanges.
• Hardness up to 67 HRC.
• Wall thickness of inner layer 7.0 mm.

Service Manual – EM070190 Page 18

TWIN-LAYER PIPES

Area #8 – Pressure Pipe on C-Valve Machines

Pressure Pipes are exposed to extreme wear due to the high pressure close to the
conveying pistons.

ESSER TWIN Layer Pressure Pipe DN 137 ( 5.4“) Page 19
• Hardness up to 63 HRC.
• Wall thickness inner layer 5.6 mm.
• Ultra wear resistant TWIN CAST ring implemented in inlet flange.

Service Manual – EM070190

TWIN-LAYER PIPES

Service Manual – EM070190 Page 20

TWIN-LAYER PIPES
Advantages of using Twin-Layer Pipes

• ESSER 900: Service life of 8-10 times compared to ST 52
• ESSER 660: Service life of 4-6 times compared to ST 52
• Less down time of the concrete pump caused by pipe replacement
• Excellent cost/performance ratio
• High profitability
• Controlled work shop costs

Service Manual – EM070190 Page 21

TWIN-LAYER PIPES

Standard Comparison DISADVANTAGES
Mild Steel
ST52 ADVANTAGES : Short service life and low protection

; Easy to weld. against break down.
; Measuring of wall thickness from the
: High costs for pipe exchange.
outside. : Extensive down time of the

; Low purchasing costs. machine.

ESSER 660 ; Durability 4-6 times compared to : Welding of pipes is only possible with
ESSER 900
ST 52. a special cooling system.

; Lower pipe installation costs and less : Measurement of wall thickness is only

down time of the machine. possible with the pipeline opened up.

; Improved cost / pumping ratio : Welding of pipes is only possible with

compared to ST 52. a special cooling system.

; Durability 8-10 times compared to : Measurement of wall thickness is only

ST 52. possible with the pipeline opened up.

; Lowest cost on pipe installation and Page 22

downtime costs.

; Lowest cost ratio per cu.yd. of

concrete pumped.

Service Manual – EM070190

TWIN-LAYER PIPES

Service Manual – EM070190 Page 23

TWIN-LAYER PIPES

Cost Comparison (Example: Boom)

Quality ST 52 ESSER 660 ESSER 900
Type of Pipe 4 mm 2,5 + 2 mm 2,5 + 2 mm

Single Layer Twin Layer Twin Layer

Price per Pipe System complete $ 4.275,00 $ 9.750,00 $ 17.550,00
Labor Cost per Pipe Change $ 660,00 $ 660,00 $ 660,00

2 Men x 6 h x $ 55.00 each $ 1.500,00 $ 1.500,00 $ 1.500,00

Loss of Revenue based on Downtime $ 256,50 $ 585,00 $ 1.053,00
Interest 6% per year
10.000 cu.yds. 50.000 cu.yds. 100.000 cu.yds.
Service Life of Pipe System

Cost per cu.yd. pumped $ 0,67 $ 0,25 $ 0,21
Investment for Parts up to 100.000 cu.yds. $ 66.915,00 $ 24.990,00 $ 20.763,00

Service Manual – EM070190 $ = US Dollar
Effective costs could be higher because of different down times
and installation times. (statement without obligation)

Page 24

TWIN-LAYER PIPES

Service Manual – EM070190 Page 25

TWIN-LAYER PIPES

Pipes are worn by
concrete abrasion.

ESSER TWIN PIPES provide
the lowest wear factor and
the highest cost efficiency.

Service Manual – EM070190 Page 26

TWIN-LAYER PIPES

Reasons for wear on delivery pipe systems

• Flow rate of concrete (cu.yd./h)
• Hardness of the sand and aggregate to be pumped
• Shape and size of aggregate
• Consistency and mix design of the concrete
• I.D. of the Pipe System
• Location of the individual pipe component within the system

Service Manual – EM070190 Page 27

TWIN-LAYER PIPES

TThhee ffoolllloowwiinngg ccoorrrreeccttiivvee
aaccttiioonnss wwiillll iinnccrreeaassee
tthhee sseerrvviiccee lliiffee
ooff tthhee ppiippee ssyysstteemm..

Service Manual – EM070190 Page 28

TWIN-LAYER PIPES

Increase the service life

Problem:

• One sided wear on pipes and elbows.

Corrective Action:

• After 15-20% of the expected service life pipes should be
rotated horizontally by approx. 120 degrees.

• After approx. 50% of the expected life the straight pipes
should be turned end for end by 180 degrees.

• The elbows should be turned end for end by 180 degrees
also.

Service Manual – EM070190 Page 29

TWIN-LAYER PIPES

Excessive Wear on Cross-Over-Pipe TWIN CAST 900 Page 30

Problem:

• The straight Cross-Over-Boom pipe
shows premature wear.

Possible causes:

• High velocity and turbulence of the
concrete after a small short radius elbow
causes the „Dish-Out“ in the following
straight pipe.

Corrective Action:

• Straight pipes with Big Mouth XL inlet
flanges should be installed after small
elbows.

• Generally the straight pipes
should be rotated.

Service Manual – EM070190

TWIN-LAYER PIPES
Abnormal wear of Elbows in Impact Position

Cause: 1 = Z-Fold
2 = Roll-Fold
• In most pumping applications the descending position of 3 = Uneasy Position
the last boom section allows the concrete to fall into the
next to the tip elbow causing ultra high impact wear. 3
2
Corrective Action:
1
• The boom should be fitted with a true Impact
Elbow. (ESSER Part. # 1-0120-292-0100-00) Page 31

• Service life will be 8-10 times longer than
regular cast elbows.

• Boom should be operated in working position 1
or 2, if possible to prevent the concrete from free
falling.

• Working in position 3 will allow the concrete to
free fall at high velocity and cause high impact wear.

Service Manual – EM070190

TWIN-LAYER PIPES
Premature wear underneath the pipe bracket (sometimes just in one spot)

Possible causes: Page 32

• Stone or dirt between pipe and bracket can cause
indentation of pipe when bracket is tightened.

• Tightening of bracket without a torque wrench, may
cause damage of hardened inner liner.

Corrective Action:

• Torquing force of 40 Nm (approx. 30 lbs.ft) must not be
exceeded.

• Pipe and bracket must be absolutely clean prior to the
assembly.

• Pipe brackets must be inspected prior to assembly.

Service Manual – EM070190

TWIN-LAYER PIPES
Damaged boom pipe under pipe bracket

Picture from inside of a damaged pipe.

Hole under the boom bracket as a piece of the layer has
broken out.

Service Manual – EM070190 Page 33

TWIN-LAYER PIPES

Wear pattern of TWIN CAST Elbows

Problem:

Elbow inlet of TWIN CAST Elbows
seems to be worn out.

Retaining lip of the
TWIN CAST wear ring
leaves the impression

of total wear at the
inlet.

Service Manual – EM070190 Reality:

Even though it looks that the inlet of the
elbow is worn out completely there is still
a inner liner thickness of 1 mm left,
enough for pumping 5.000 – 7.000 m³
(6,540 – 9,156 cu.yds.) additional.

Page 34

Old Design TWIN-LAYER PIPES
Wear pattern of TWIN CAST Elbows

New Design

Retaining lip Big Mouth flange with
better wear indication

When the inner liner is worn down to the retaining lip, there is still further life left (Covered by the retaining lip).
Further usage is possible. In this situation the Elbow should be turned around (END for END). The wall
thickness of the flange inside the groove for the coupling should be measured.

Service Manual – EM070190 Page 35

TWIN-LAYER PIPES

Measurement of wall thickness of elbows

(to evaluate the future date of exchange)

ESSER TWIN PIPE 660

Dia.: DN 125

Quality: 660

Wall thickness: 7.1+3.6

Wall thickness at P1 P2
measuring points Approx. 10.7 mm
Approx. 4.1 mm Approx. 9.4 mm
Wall thickness
New Approx. 3.6 mm

Wall thickness Based on raw material tolerances, nominal wall thicknesses may slightly vary.
Suggested exchange Page 36

Service Manual – EM070190

TWIN-LAYER PIPES

Measurement of wall thickness of elbows

(to evaluate the future date of exchange)

ESSER TWIN CAST 900

Dia.: DN 125

Quality: 900

Wall thickness: 7.0+2.0

Wall thickness at P1 P2
measuring points Approx. 13.5 mm
Approx. 7.0 mm Approx. 9.5 mm
Wall thickness
New Approx. 3.0 mm

Wall thickness Based on raw material tolerances, nominal wall thicknesses may slightly vary.
Suggested exchange Page 37

Service Manual – EM070190

TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

ESSER TWIN PIPE 660

Dia.: DN 125

Quality: 660

Wall thickness: 2.5+2.0

Wall thickness at P1 P2
measuring points Approx. 4.6 mm
Approx. 2.5 mm Approx. 8.3 mm
Wall thickness
New Approx. 3.3 mm

Wall thickness Based on raw material tolerances, nominal wall thicknesses may slightly vary.
Suggested exchange Page 38

Service Manual – EM070190

TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

ESSER TWIN CAST 900

Dia.: DN 125

Quality: 900

Wall thickness: 2.5+2.0

Wall thickness at P1 P2
measuring points Approx. 4.6 mm
Approx. 2.5 mm Approx. 7.0 mm
Wall thickness
New Approx. 4.9 mm

Wall thickness Based on raw material tolerances, nominal wall thicknesses may slightly vary.
Suggested exchange Page 39

Service Manual – EM070190

TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

ESSER TWIN PIPE 660

Dia.: DN 125

Quality: 660

Wall thickness: 5.6+3.0

Wall thickness at P1 P2
measuring points Approx. 8.8 mm
Approx. 3.7 mm Approx. 8.3 mm
Wall thickness
New Approx. 3.7 mm

Wall thickness Based on raw material tolerances, nominal wall thicknesses may slightly vary.
Suggested exchange Page 40

Service Manual – EM070190

TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

ESSER TWIN CAST 900

Dia.: DN 125

Quality: 900

Wall thickness: 5.6+3.0

Wall thickness at P1 P2
measuring points Approx. 8.8 mm
Approx. 3.7 mm Approx. 9.2 mm
Wall thickness
New Approx. 3.1 mm

Wall thickness Based on raw material tolerances, nominal wall thicknesses may slightly vary.
Suggested exchange Page 41

Service Manual – EM070190

Contact TWIN-LAYER PIPES

ESSER-WERKE GmbH & Co. KG ESSER TWIN PIPES LLC.
Zum Puddelhammer 25 2700 Wisconsin Street
59581 Warstein Sturtevant, WI 53177
GERMANY USA
Tel. +49 (2902) 896 0 Tel. +1 (262) 884 8805
Fax +49 (2902) 896 30 Fax +1 (262) 884 8803
E-Mail [email protected] E-Mail [email protected]
Web www.esser-werke.de Web www.esserllc.com

LTB Le Tuyau Bi Metal ESSER TWIN PIPES LLC.
13 Avenue de l'Europe 147 Airpark Industrial Road
67300 Schiltigheim Alabaster, AL 35007
FRANCE USA
Tel. +33 (388) 564 500 Tel. +1 (205) 621 2454
Fax +33 (388) 564 711 Fax +1 (205) 621 9739
E-Mail [email protected] E-Mail [email protected]
Web www.essertwinpipes.com Web www.esserllc.com

Service Manual – EM070190 ESSER TWIN PIPES Shanghai Office
Room K. 20th Floor - No. 800 Nanjin Rd. (E)
200001 Shanghai
CHINA
Tel. +86 (2163) 223 166
Fax +86 (2163) 248 669
E-Mail [email protected]
Web www.essertwinpipes.com

Page 42

ZWEILAGENROHRE

Service Manual– EM070190 DE Seite 1

Der Maßanzug für ZWEILAGENROHRE
Ihre Betonpumpe
Seite 2
Service Manual– EM070190 DE

ZWEILAGENROHRE
Das SK Förderleitungssystem

Bis 2° abwinkelbar, drehbar und dennoch dicht.

Service Manual– EM070190 DE Seite 3

ZWEILAGENROHRE

Das Problem von SK Förderleitungen
aus handelsüblichen Stahlsorten

Kurze Lebensdauer von Normalstahl. Ungleicher Verschleiß an den Rohrein-
Gestein ist härter. und Ausläufen durch Spalt und Versatz
zwischen zwei Rohren.

Service Manual– EM070190 DE Seite 4

ZWEILAGENROHRE
Verschleißanfällige Stellen benötigen spezielle Komponenten

Verschleiß am Ausgang der Verschleiß an Rohrleitungsteilen Fallbögen, die am Ende des Mastes
Reduzierung. in den Drehpunkten des Mastes. installiert sind, werden durch Prall-
verschleiß zerstört.

Service Manual– EM070190 DE Seite 5

ZWEILAGENROHRE

Welche wesentlichen Qualitäten für SK Förderleitungen gibt es?

• ST 52

Rohre aus Normalstahl kombiniert mit Gussbögen.
Einfach zu schweißen, nur kurze Lebensdauer, verschleißen ungleichmäßig.

• Rohre mit veränderter chemischer Zusammensetzung des Stahls

Sowohl billigere Rohre aus ST 37 als auch teurere Rohre (z.B. vergütete Rohre) haben
keine wesentliche Verbesserung der Kostensituation bewirkt.

• Einlagig gehärtete Rohre

Einfach zu schweißen, Wanddickenmessung von außen möglich.
2-3fache Lebensdauer und Kosten gegenüber ST 52 und damit keine wesentliche
Verbesserung der Kostensituation.

Service Manual– EM070190 DE Seite 6

ZWEILAGENROHRE

Welche wesentlichen Qualitäten für SK Förderleitungen gibt es?

• Zweilagige Förderrohre (ESSER 660)

Ca. 4-6 mal haltbarer und nur 2-3 mal teurer als Standrad ST 52.
Der Verschleißfaktor wurde wesentlich verbessert im Vergleich zu ST 52 Rohre.
Schweißen dieser Rohre nur mit spezieller Kühlvorrichtung möglich.
Die einzelnen Rohrleitungsteile verschleißen noch ungleichmäßig im Verhältnis zueinander.

• Zweilagige Förderrohre mit Guss Einlage (ESSER 900)

Mit Spezialverstärkungen und TWIN CAST Bögen die wirtschaftlichste Lösung.
Ca. 8-10 mal haltbarer und nur 4 mal teurer als ST 52.
Gleichmäßiger Verschleiß über die gesamte Rohrleitung.

Service Manual– EM070190 DE Seite 7

ZWEILAGENROHRE

Förderleitungssysteme für den Mast

ESSER TWIN PIPE 660 ESSER PIPE TWIN CAST 900
DN 125 - 4,5 mm (2,5+2,0) DN 125 – 4,5 mm (2,5+2,0)

• Härte bis zu 63 HRC. • gehärtetes Innrohr bis zu 67 HRC.
• 4-6fache Standzeit gegenüber St 52. • 8-10fache Standzeit gegenüber ST 52.

Je nach Ausführung und Größe des Betonverteilermastes auch erhältlich in den Wandstärken:
2,0+2,0 mm / 2,5+1,5 mm / 2,0+1,5 mm sowie in den Nennweiten 130 mm / 117 mm / 112 mm / 100 mm.

Service Manual– EM070190 DE Seite 8