Schwing concrete pumps are 12% more fuel efficient.

VG Sakthikumar,
Managing Director,
Schwing Stetter India.

Schwing Stetter is ahead of the industry competition in terms of introducing new products.

Schwing Stetter India is a leading manufacturer of concreting equipment in India, including the concrete pumps and we have a very wide range of these pumps catering to the demands of small contractors / projects right up to pumps that are required for very tall constructions of 200 mtrs high and above, says VG Sakthikumar, Managing Director, Schwing Stetter India. Excerpts from the interview

What is the impact of telematics and machine control technologies on concrete pumps manufacturers, especially with regard to providing better performance?  

The performance of the Schwing concrete pump with telematics can be monitored live to ensure that all data are captured at any given point of time. The telematics device will log all the data related to operation as well as the output of the concrete pump. In case of any critical issues, the alarms can be configured to ensure the maximum availability of the equipment (proactive maintenance). Also one can get the daily output details on the web. In addition, the wear part life and cost spent towards maintenance or per cubic meter cost can be arrived based on the life of wear parts.

If the process is completely equipped with telematics solution, one can get the arrival time of the transit mixer to the concrete pump location. So that we can have controlled RPM when there is no concreting for a longer duration. Also to ensure stop time during concreting, the concrete flow rate can be controlled, so that the pump will be in operation till the next truck reaches the site. This controlled RPM will help in fuel efficiency.

How do you ensure less wear and tear with the use of telematics solutions?

The log data will give us the periodic maintenance alerts which will help us in increased Schwing Stetter machine life. This will reduce the wear and tear of the parts used. For example on time servicing like greasing, lubrication, oil change will extend the life of wear parts. The invented and patented Schwing rock valve technology is very rugged and it allows pumping with higher concrete pressure to reach higher output at great height. Rebuilding of rock valve is much easier in less time. Schwing provides hard wear parts for critical application to achieve longer change interval. Special concrete pipes with various thick and inner abrasive coating are also available.

How user-friendliness & eco-friendly are your range of pumps?  What role telematics plays here?

The regular maintenance and controlled RPM based on telematics input will help in eco friendliness of the product. This will reduce the air pollution to some extent.  As far as user friendliness is concerned all the equipment are designed and developed based on the feedback from various customers and market needs. In addition, telematics ensures the availability of data from any location. So that location dependency can be reduced.

User friendliness is imbibed in each of our product line. We offer vector control system in boom pump which constantly tracks data for mode of failure, reason of failure and tackles future repetition of the problem; also we can see all the working data of the machine right from the commissioning stage. All the controls offered by SSI has options for remote diagnosis.

Could you throw some light on the concept of green pumps?

Fuel efficiency is one major parameter that a customer looks into, given the bearing it has on the design of green products. Also concepts such as low lifecycle cost, faster return of investments, cost per cubic meter, all have a positive impact on OEMs, who have launched a variety of pumps to suit the requirements of the customer, coupled with innovative service packages. New operating system gives all the information about pumping hours, running hours, wear and tear. Schwing Stetter is ahead of the industry competition in terms of introducing new products. Our new product launches are Schwing stationary concrete pump SP1015D/HD, SP1420 and Schwing heavy duty concrete pump 4507.

What about the ensuring increased fuel efficiency?

Schwing concrete pump has an open loop hydraulic circuit which result in high fuel efficiency because of less heat generation and efficient energy transfer. Ideally suited for the hot Indian climate, tests have proved that Schwing concrete pumps are at least 12% more fuel efficient than the similar pump of competition.

What are the latest trends in the design of distributor booms to ensure uniform and low-vibration operation?

Schwing concrete placer boom RVH18 is a concrete distributor with DN 125 pipeline and bends with Schwing interchangeable pipe couplings. This distributor is with 3-section hydraulic boom, has four self-supporting legs, foldable to make it within transport dimensions.

The lightweight design of pedestal and split boom design enables easy lifting, keeping control of assembly weight in minimum. RVH18 boom can reach 18m, with 3m concrete hose fixed at the end. The leg can be placed on floor or barge or can be fixed in slip-form base. The RVH18 is provided with a sophisticated remote control system with electric motor power pack. The movements of the boom can be controlled precisely.

The counter weight for all operation with power pack is resting on a slewing base column. Suitable safety devices are provided to ensure accident-free and safe operation of the stationary boom. RVH18 will enhance the mechanized concrete pouring and can avoid the cumbersome process of laying the pipelines. This can speed up the concrete pour with reduced manpower.

Tell us about the engine and uniqueness of hydraulic system used?

Schwing concrete pumps (as well as our sludge pumps) are hydraulically driven, twin-cylinder pumps. Their hydraulic drive and control systems (called the ‘brain’) have all been designed by Schwing engineers specifically for applications in concrete and sludge pumps. Because of this, they fulfil more than just the necessary functions of a hydraulic pumping system. The combination of the two systems achieves an extremely steady and gentle pumping pattern, even at maximum outputs.

Pump Schematic: Hydraulic oil is pumped under pressure to the working cylinders. The hydraulic brain block runs through a compulsory control sequence and extends one of the working cylinders, while the other one retracts at the same time.

This ‘boxer stroke’ is transferred to the concrete pumping cylinders so that one cylinder pumps draw in concrete and the other one pumps concrete into the connected pipeline. The switch point in the system (the concrete valve) is stroked at the same time to steer the flow of concrete.

What is the scenario looks like with regard to the use of and potential of high pressure concrete pumps?

High pressure concrete pumps are predominantly used in high rise projects and power projects. High grade of concrete is used in the construction of nuclear power plants, real estate, memorials, roads, railways, etc. Wherever concrete is produced, Schwing Stetter machinery finds its place be it in roads, railways, ports, rural infrastructure, power, smart cities, irrigation, water supply and
sanitation, etc.

What is the current demand-supply scenario for concrete pumps? 

Concrete pumps are at a growing rate of 12-15% growth going forward YOY till 2020. The market for truck mounted concrete boom pumps in India holds a large share in the global market and is expected to grow at a CAGR of 5.8% over the period of 2017 – 2025.  Roads, railways, power, irrigation, water supply and sanitation, real estate, rural infrastructure, ports, airports etc drive the demand for concreting and non concreting product line.

What is the present conversion factor for cement for RMC in today scenario?

Affordable housing projects and Pradhan Mantri Awas Yojana has given a boost to the RMC in today’s scenario which in turn boosts the business of concrete pumps, batching plants and concrete transit mixers. The real estate activity, where the concrete pumps are extensively used is still sluggish. The current usage of pumps is hence predominantly at various other construction projects and the concrete pump business is therefore not growing to the extent that we anticipated. In the last few months, we are seeing an increase in the demand for boom pumps as well as high pressure pumps, which are required for long distance pumping or for high-rise construction.

How have you addressed the challenges of availability skilled technicians and operators for these products?

As a part of our vision of empowering the customers with knowledge and expertise, an exclusive Training Centre was setup in 2004 at our HO & Works in Irungattukottai, Sriperumbudur, Kancheepuram. The training centre with lecture halls to train up to 100 personnel at a time, has got the facility of giving computer based training programs with audio visual aids, training simulators, fully fledged technical library, cut model display area, cafeteria and locker facilities for the trainees. The training centre imparts primary and advanced courses on operation & maintenance, safety & troubleshooting for deriving the best benefits out of Schwing Stetter equipment.

Further to cater to the customers in their own region, we have come up with regional training centres at New Delhi, Kolkata, Hyderabad. Schwing Stetter India is the first organization to be accredited under concrete pump operators course in the whole of India under the Pradhan Mantri Kaushal Vikas Yojana of National Skill Development Council.

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