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Concrete PumpingApplications
Concretepumping
Reliability, safety and efficiencyare more important than ever for the pumping of
ready-mixed concrete. Especially for deadline-
bound projects, conveying pipes must not fail.
Single-layer ST52 pipes will wear out within very
short periods of time. This results in high costs
for service providers in the ready-mixed
concrete industry because of downtime due to
repairs, service / maintenance work or the
replacement of components.
ESSER WERKE have developed and produced
conveying pipes, elbows and special delivery
line parts for truck-mounted concrete pumps,
truck mixers concrete pumps or concrete
distributing booms since 1980. The two-layer
ESSER TWIN PIPES achieve a service life,
which is significantly longer than ST52 pipes.
Our pipes are checked for their pressure
resistance at regular intervals. The hardness of
TWIN PIPE pipes is constant over the entire
pipe length so that service intervals can be
scheduled more easily. All of our products are
manufactured subject to the pump manu-
facturers' specifications.
Today, ESSER conveying pipes are used
globally.
2
Concretepumping
Our partnersManufacturers from all parts of the world rely on
ESSER conveying pipe systems. We supply
boom pipes and deck pipes, elbows, reducers
and special delivery line parts for concrete
pumps to the following OEM manufacturers:
• Cifa
• Elba
• Jun Jin
• Liebherr
� Putzmeister
• Schwing
• Sermac
• and many other
3
Boom pipes
4
ESSER 900
The special hardening process and high-quality welding
process ensure that ESSER pipes achieve a service life,
which is many times longer than that of commonly available ST52 pipes with the same wall thickness. Boom pipes
shall not exceed the specified weight in order to ensure that the stability of the machine is not endangered. All
ESSER pipes are manufactured in accordance with the weight specifications by concrete pump manufacturers.
Conveying pipes for booms are available in two different quality levels. We recommend that you use the ESSER
900 XL pipe where you get extreme wear e.g. behind an 10-45° elbow. Those pipes have an extended inlet weld
collar to compensate the wear.
* Only for short distances at critical wear points inside the boom.
** Compared with commonly available ST52 pipes. Medium concrete.
ESSER 700Material Double layer, hardened inner pipe
Inlet Big Mouth weld collar, hardened inner ring
Outlet Big Mouth weld collar, hardened inner ring
Hardness (acc. Rockwell) Up to 63 HRC
Nominal diameter (DN) [mm] DN 100 DN 125
Weld collar size [inch] 4,5" SK 5,5" SK
Wall thickness [mm] 2,0 + 2,0 2,0 + 2,0
(Inside and outside wall) 2,5 + 2,0
Length [mm] 100 - 6000
Working pressure (P) [bar] 85
Service life factor* 5
Material Double layer, hardened inner pipe
Inlet Big Mouth weld collar, hard cast inner ring
Outlet Big Mouth weld collar, hard cast inner ring
Hardness (acc. Rockwell) Up to 67 HRC
Nominal diameter (DN) [mm] DN 112 DN 117 DN 125
Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK
Wall thickness [mm] 2,0 + 2,0 2,0 + 1,5 2,0 + 2,0
(Inside and outside wall) 6,3 + 1,5* 3,0 + 1,5
Length [mm] 100 - 6000
Working pressure (P) [bar] 85
Service life factor** 10
* Compared with commonly available ST52 pipes. Medium concrete.
Boom pipes
5
ESSER 900 XLMaterial Double layer, hardened inner pipe
Inlet Big Mouth weld collar, hard cast inner ring
XL Flange extension
Outlet Weld collar, hard cast inner ring
Hardness (acc. Rockwell) Up to 67 HRC
Nominal diameter (DN) [mm] DN 112 DN 117 DN 125
Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK
Wall thickness [mm] 2,0 + 2,0 2,0 + 1,5 2,0 + 2,0
(Inside and outside wall) 3,0 + 1,5
Length [mm] 100 - 6000
Working pressure (P) [bar] 85
Service life factor* 10
* Compared with commonly available ST52 pipes. Medium concrete.
6
The special hardening process and high-quality welding
process ensure that ESSER pipes achieve a service life,
which is enormous longer than the commonly available ST52 pipes. ESSER recommends standard deck pipes in
a thick-walled design. Thick-walled conveying pipes for the deck are available in two different quality levels:
ESSER 700
ESSER 900
Material Double layer, hardened inner pipe
Inlet Big Mouth weld collar, hardened inner ring
Outlet Big Mouth weld collar, hardened inner ring
Hardness (acc. Rockwell) Up to 63 HRC
Nominal diameter (DN) [mm] DN 100 DN 125
Weld collar size [inch] 5,5" SK 5,5" SK
Wall thickness [mm] 4,5 + 3,2 5,6+3,0
(Inside and outside wall)
Length [mm] 100 - 6000
Working pressure (P) [bar] 85
Service life factor* 5
* Compared with commonly available ST52 pipes. Medium concrete.
Material Double layer, hardened inner pipe
Inlet Big Mouth weld collar, hard cast inner ring
Outlet Big Mouth weld collar, hard cast inner ring
Hardness (acc. Rockwell) Up to 67 HRC
Nominal diameter (DN) [mm] DN 125
Weld collar size [inch] 5,5" SK
Wall thickness [mm] 5,6+3,0
(Inside and outside wall)
Length [mm] 100 - 6000
Working pressure (P) [bar] 85
Service life factor* 10
* Compared with commonly available ST52 pipes. Medium concrete.
Deck pipes
7
Elbows
ESSER 700
ESSER 900
Since elbows are subjected to heavier wear than straight
pipes, ESSER supplies conveying elbows with a bigger
wall thickness in a two-layer design. The layout and geometry of the elbow are ideally suited for stress. The internal
layers of the 700 series are hardened. For the 900 series, the internal elbow is made of a particularly wear-resistant
cast alloy. Conveying pipes must not exceed the specified weight in order to ensure that the stability of the machine
is not endangered. All ESSER elbows are manufactured in accordance with the weight specifications by concrete
pump manufacturers.
Material Double layer, hardened inner elbow
Inlet Big Mouth weld collar, hardened inner ring
Outlet Big Mouth weld collar, hardened inner ring
Hardness (acc. Rockwell) Up to 63 HRC
Nominal diameter (DN) [mm] DN 100 DN 125
Weld collar size [inch] 4,5" SK 5,5" SK
Wall thickness* [mm] 5,0 + 3,2 7,0 + 4,0
(Inside and outside wall)
Angle [degree] 5° - 90°
Working pressure (P) [bar] 85
Service life factor** 5
Material Double Layer.
Inner elbow out of special hard cast alloy
Inlet Big Mouth weld collar, hard cast inner ring
Outlet Big Mouth weld collar, hard cast inner ring
Hardness (acc. Rockwell) Up to 67 HRC
Nominal diameter (DN) [mm] DN 112 DN 117 DN 125
Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK
Wall thickness [mm] 5,0 + 2,0 5,0 + 2,0 7,0 + 2,0
(Inside and outside wall)
Angle [degree] 5° - 90°
Working pressure (P) [bar] 85
Service life factor** 10
* The wall thicknesses depend on the geometry and can vary depending on the dimensions and angles.** Compared with commonly available cast elbows. Medium concrete.
* The wall thicknesses depend on the geometry and can vary depending on the dimensions and angles.** Compared with commonly available cast elbows. Medium concrete.
8
Reducers
In reducers, flow speed and also the pressure is changing.
As a result, the wear increases towards the reducer outlet.
For this reason, we have optimized the wear protection at particularly critical points, especially for our reducers of
the 900 series.
ESSER 700
ESSER 900
* Compared with commonly available ST52 pipes. Medium concrete.
Material Compound steel, double layer,
hardened inner pipe
Inlet Double weld collar, hard cast inner ring
Inlet type SK or OEM specific
Outlet Big Mouth weld collar, hard cast inner ring
Hardness (acc. Rockwell) Up to 63 HRC
Nominal diameter (DN) [mm] DN 125 / 100 DN 150 / 125
DN 125 / 112
DN 125 / 117
Wall thickness [mm] 4,0 + 4,0
(inside- and outside wall)
Length [mm] > 500
Working Pressure (P) [bar] 85
Service life factor* 5
Material Double Layer.
Inner pipe out of cast alloy.
Inlet Hard cast inner ring
Inlet type SK or OEM specifi c
Outlet Big Mouth weld collar, hard cast inner ring
Hardness (acc. Rockwell) Up to 67 HRC
Nominal Diameter (DN) [mm] DN 150 / 117
DN 150 / 125
Wall thickness* [mm] 6,0 + 4,0
(Inside and outside wall)
Length [mm] > 500
Working Pressure (P) [bar] 85
Service life factor** 10
* The wall thicknesses depend on the geometry.** Compared with commonly available ST52 pipes. Medium concrete.
ESSER TX with an integratedwear indicator
9
InnovationsDue to the construction of the two-layer pipe, it is not possible to use an ultrasound measuring unit for measuring
the wall thickness. Therefore, the residual wall thickness needs to be measured manually using a measuring
probe. Our new TX system allows the use of a conveying pipe up to its maximum service life, and continuous
measuring is no longer necessary. When the wear layer of the internal pipe has been worn down, the laitance will
exit through small channels. This component must be replaced and should be reordered immediately in order to
ensure safety. The exit point is secured against laitance ejection using a metal clamp.
ESSER 900 TXBoom pipe
With an integrated wear indicatorfor ensuring maximum usage.
ESSER 700 TXReducer
With an integrated wear indicatorfor ensuring maximum usage.
Material Double layer, hardened inner pipe
Inlet Big Mouth weld collar, hard cast inner ring
XL Flange extension
Outlet Big Mouth weld collar, hard cast inner ring
Hardness (acc. Rockwell) Up to 67 HRC
Nominal diameter (DN) [mm] DN 112 DN 117 DN 125
Weld collar size [inch] 5,5" SK 5,5" SK 5,5" SK
Wall thickness [mm] 2,0 + 2,0 2,0 + 1,5 2,0 + 2,0
(Inside and outside wall) 3,0 + 1,5
Length [mm] 100 - 6000
Working pressure (P) [bar] 85
Service life factor* 10
* Compared with commonly available ST52 pipes. Medium concrete.
* Compared with commonly available ST52 pipes. Medium concrete.
Material Compound steel, double layer,
hardened inner pipe
Inlet Double weld collar, hard cast inner ring
Inlet type SK or OEM specific
Outlet Big Mouth weld collar, hard cast inner ring
Hardness (acc. Rockwell) Up to 63 HRC
Nominal diameter (DN) [mm] DN 125 / 100 DN 150 / 125
DN 125 / 112
DN 125 / 117
Wall thickness [mm] 4,0 + 4,0
(inside- and outside wall)
Length [mm] > 500
Working Pressure (P) [bar] 85
Service life factor* 5
Back-end kits
ESSER produces complete pump outlets for machine
types of different manufacturers.
10
Examples of different back-end kits in ESSER 900 quality
Elbow 42° DN125
Reducer DN 150 / 125
Elbow 90° DN150with holder
Elbow 50° DN125with extension
ReducerDN150 / 125
Elbow 90°DN150
Swivel ElbowDN 180/150(Version 1)
Swivel ElbowDN 180/150(Version 2)
Connection elbow 14°DN 180
Swivel Elbow 90°DN 180 / 150(Version 1)
Swivel Elbow 90°DN 180 / 150(Version 2)
Elbow 45° DN125with extension
ReducerDN 150 / 125
Elbow 90°DN 150
Special components
We also manufacture special delivery line components in
two-layer design. We work closely with concrete pump
manufacturers in order to find tailored solutions for their specific requirements.
Elbow with extension Rib pipes
Impact- and turret elbow Multiplex elbows
Special elbows Step elbows
11
12
Performance optimisation
Typically, concrete conveying pipes show uneven
wear. The reducers, elbows or straight pipes behind
elbows have different service lifes as compared to the
places in the line with less wear stress. Therefore, the
operating times on job-sites are not easy to schedule
because one cannot foresee when a component
is going to fail. Worn-out pipes must be provisionally
sealed on site. In such an event, it will be difficult, and
sometimes impossible, to retract (suck back) the
cleaning ball. Very often the entire pipeline was
replaced although the rest of the them would have
lasted much longer. The downtime, for frequent
ESSER 700.
For normal delivery volume or average wear we
recommend pipe components of the ESSER 700
series. All parts are manufactured in a two-layer
design. Our standard layout for efficient concrete
pumping and conveying.
ESSER 700 UPGRADE(ESSER 700 / ESSER 900)
For enhancing particularly wear-prone pipe points by
higher-quality components from the ESSER 900
series.
Example:
= Elbow after reducer
(ESSER 900 with extension)
= Turret Elbow (ESSER 900)
= Turret Pipe (thick walled type)
= Boom Crossing (ESSER 900)
= Impact Elbow
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4
5
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2
3
5
5
4
Performance optimisation
13
replacement of individual pipes or premature
replacement of the entire pipeline increase both the
wear costs and the number of necessary service
intervals. ESSER components are adjusted to the
specific requirements of the individual wear points
inside the conveying pipe. Due to the use of different
qualities at critical points, a conveying pipe can be
optimised by being adapted to the individual
requirements.
ESSER 900.
The optimum solution for high delivery volume and
heavy wear stress. The almost even wear rate
ensures that this system is particularly efficient for
bigger concreting projects.
ESSER 900 / ESSER 900 XL.
Boom pipes behind elbows show up to 50% more
wear. Turbulence, which is created by the change of
direction in the elbow, specifically attacks the inlet area
of the pipe.
To solve the problem, we recommend the ESSER 900
XL. For all ESSER 900 XL pipes, only the inlet flanges
have been reinforced over a certain distance with a
thicker internal wall. The additional weight is minimal
and within the pump manufacturer's tolerance range.
Example:
= ESSER 900 XL1
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1
Performance
14
What is the performance
of your pipes…?
170 bar test pressure
ESSER pipes for concrete pumps are designed for an operating
pressure of up to 85 bar. Our pipes are tested for pressure
resistance at regular intervals.
Constant hardness
The hardness / strength of ESSER pipes is constant over the
entire pipe length. As a result, the pipes show even wear and their
service intervals can be scheduled easily.
No additional weight
ESSER pipes are designed according to manufacturer weight
specifications. Therefore, the compliance with the statics
characteristics of the machine is ensured in all possible machine
positions.
Standardised weld
A pipe is only as good as its weld. Our welding process is in
accordance with standards specifications.
Increased wear-resistance
The service life of ESSER TWIN PIPES is up to 25% higher
compared to other two-layer pipes on the market.
Please contact us for
further information!
+49 2902 896 0
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Wear characteristics ofESSER pipes
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2
4
6
8
10
Serv
ice
LIf
e (
in c
om
pa
riso
n)
ST52ESSER 400= 2 x ST52
ESSER 700= 5 x ST52
ESSER 900= 10 x ST52
SERVICE LIFE(Compared with commonly available ST52 pipes
of the same wall thickness)
ESSER-WERKE GmbH & Co. KG
Zum Puddelhammer 25
59581 Warstein
Germany
Tel. +49 2902 896 0
Fax +49 2902 896 30
eMail [email protected]
Home www.esser-werke.de
LTB · Le Teyau Bi Metal
13 Avenue de l’Europe
67300 Schiltigheim
France
Tel. +33 3885 64 500
Fax +33 3885 64 711
E-Mail [email protected]
Home www.essertwinpipes.com
ESSER Partner
EM
120029 G
B 1
50331