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| Micro-concrete pump to place Micro-concrete high strength self flowing grout |
Preamble:
Struct-Mast Engineers and their team of engineers has innovated, conceptualized, designed, fabricated, assembled the Micro-concrete pump to place high strength cementitious grout into forms to offer apt solutions to puzzling problems in pumping. This apparatus and is intended to do the continuous pumping and placement of self-flowing high strength
cementitious grout into restrained area.
The assembly is mounted on a fixed or
mobile frame. There is a continuous pumping of the self-flowing grout which is supplied
to an intake port of a screw-type, positive-displacement pump and discharged
from this through a conduit pipe to placement site into forms on a continuous
basis.
Struct-Mast Engineers are using this pump successfully to cater the needs of their client to restore the RCC structures. We have intentions to develop this pump on large scale and have a desire to set up a marketing set up including awarding dealership.
Actual users and dealers who are interested in the pump may contact us on structmast@yahoo.co.in or call Mr. Jayant Sheth on + 91 9820291968 or Mr. Chintan Sheth on + 91 9820857365 or to call our office + 91 22 23452248 for better deal.
Consulting engineers, Consulting Architects, prospective Clients and research scholars also may contact us how to specify the pump in their special conditions of contract to achieve good quality works to place high strength micro-concrete grout which will receive prompt attention from us.
History:
Struct-Mast Engineers during their tenure as specialist contractors had come across difficult turns to place high strength grout in to inaccessible areas like soffit of the slab, other concrete structures surrounded by facilities like piping in refineries, power plants, cement companies, other major industrial plants, deep seated marine structures surrounded by sea water through out the service life and many more similar situation wherein the conventional repairs are carried out hand applied applications with lot many limitations and major being strength development and durability. To keep up our goal to achieve best results for the beloved clients and to place rendering as specified by the consulting engineer and the consulting architects, our innovative engineers conceptualised the pump into realities to keep space with the modern technology which has developed self flowing, self compacted and high strength micro-concrete.
Application in the Field:
The self-flowing self-compacted high strength cementitious
grouts have many applications in the repair sector, new construction, tunnel
lining etc. of civil engineering, empty pipe filling, soil stabilization /
cavities filling in geo-technical works, such as for filling gap between base
plate and concrete pedestals, filling micro-concrete in to beams and column
locations where reinforcement is found congested and concrete cannot flow,
between existing prepared surface of damaged concrete and shuttering location
to strengthen and repair RCC members, abandoned pipelines locations and other
large voids in the earth, and for grouting of tunnel liners and similar
structures. These grout is mixed into the mixers as ready to mix micro-concrete.
Because of the high-strength along with other properties like self-flowing, cohesive mix, the cement grout which achieves strength in relatively shorter period compared to normal cement concrete and being non-shrink type the damaged structures retains the strength as desired and the structure is expected to perform which otherwise would have been under risk of not performing under service load. This results in great cost savings, especially when structures are critical structures. Other advantages of the high-strength grout is because it is fluid and non-shrinking, the need for contact grouting or bonding coat is eliminated.
Advantage of the pump:
- Although other grout namely application of in geotechnical field of civil engineering cement is modified with fly ash or bentonite and the grout is highly advantageous material for grouting, backfilling, void filling, and so forth, its success in many of these applications has been limited to a significant degree by the manner in which it is conventionally prepared and subsequently pumped with the pump which will not segregate the individual constituents namely sand, cement, fine aggregates and other additives and or ad-mixture due to every cross section of grout remains same as it is existing.
- The conventional batch-process approach and grouting under gravity or using other centrifugal type of pumps exhibits certain inherent inefficiencies and disadvantages, especially when it comes to large fill jobs.
- It may be possible to prepare batches of cement grout which are big enough to complete relatively small grouting jobs, this is simply not feasible in the case of larger jobs, such as the filling of abandoned pipelines, which may call for large quantities in terms of several cubic meter of grout. Obviously, the repeated starting and stopping of pumping which is involved in a batch process introduces a strong element of inefficiency on such projects, especially being that large crews of workers may be left standing idle between the placing of each batch. This enhances the costs.
- The need to mix up separate batches of grout and pump these individually invariably leads to quality control difficulties. Apart from mix variations which occur inevitably from batch-to-batch, the batch-type processes are inherently incapable of permitting adjustment of the quality of the grout as it is being pumped.
- Though the cohesive structure of the fluid grout is very stable, and will withstand high pressures without loss of integrity, significant passage of time may cause segregation due to friction between the grout and the piping or surface in contact with flowing grout through which it is pumped. These friction losses are somewhat unpredictable, and naturally become more serious as pumping distances increase. The inability of the batch-type processes to adjust the quality of the grout to compensate for observed friction losses means that an entire batch of grout may be placed at the placement location with the constituent structure being significantly deteriorated due to friction loss, resulting in a severe decrease in the volumetric yield of the batch.
- Another serious problem which has been encountered with such conventional grouting systems, particularly when filling abandoned pipelines and other elongate voids or placing grout underneath large span slabs for restoration purpose, stems from their inability to deliver the grout continuously at a high volume rate over sustained periods. As was noted above, the cohesive structure of the grout is very stable so long as there is free liquid along with evenly distributed constituents of the grout in the mixture, and so this can be pumped at relatively high pressures. However, once hydration of the grout proceeds to the point where it takes an initial set, the cohesive structure ceases to exist and is replaced by hard and harsher mortar which is maintained only by the cement paste which surrounds it; if this is subjected to external pressure, as by the pumping of additional grout adjacent to or on top of the first, the hard / harsher mortar structure will collapse very easily, resulting in a severe segregation of the cementitious mortar and blocking / choking of the paths as good as loss of volumetric yield. In simple words, it is very difficult to avoid this when using a batch-type process, since the process is slow by its own very nature and placement will periodically halt while another batch is being prepared, and the grout will continue to set during these pauses; the pumps and related equipment which are conventionally employed in these processes are not suited to high placement rates.
- At times due to head existing between pump location and grout placement, there is back pressure causing choking of pumping grout at the delivery point causing frequent closure of the operations and one cannot deliver quality works. This problem has been resolved in our apparatus and it’s system by proving hopper which hold the grout and contains the back pressure as well as maintaining inclination of the screw and complete assembly.
All above problems has rendered the conventional techniques facing lots of limitations and the pump innovated has an edge.
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Our mission:
- To successfully develop, produce and sell high quality micro-concrete pump and pumping systems and contributing to a better quality of life in healthier environment.
- To strive to become world class leading pump manufacturer to offer our Clients user's friendly, reliable, efficient, saves on wastage of material and sustainable product.
