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INSTRUCTION OF SPUN ROLL PIPE MACHINE

1. Summary

Suspension Roller type Concrete pipe machine is a kind of perfect

INSTRUCTION OF SPUN ROLL PIPE MACHINE

machine and equipment to produce Reinforced concrete pipes and

Pre-stressed concrete pipe. This machine is capable to make pipes with

diameter from 300-2400mm and with length from2-5 meters. We can

design many kinds of the pipe joint, including flush joint, widely

socket&spigot joint, male&female joint. And all the concrete pipes are

used in administrative drainage, agricultural field irrigation, road

culvert and deep water well.

Working Principle: this machine use the Roller to support the pipe

mould, and produce the roller force to concrete in the mould. When the

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roller rotate at a high speed, the concrete in the mould will spread in the

inner wall of the pipe mould and form a cement pipe with the

centrifugal force, and when the mould with the inner concrete pass on

the roller,the concrete between the mould and the roller will be

compacted solid to form a pipe.

Character of Suspension Roller type Concrete Pipe Machine

(1) Short production Cycle: because of the good effect of the roller to

compact the concrete, every pipe just need 3-5 minutes with high speed

roller rotation.

(2) This Pipe machine use the dry cast material, there will no waste

cement mud, then it wont pollute the environment.

(3) During the production, the noise is low, it is about 80-90 DB

(4) The Concrete Pipes are with high pressure load and with high

production efficiency.

2. Main Technical Parameter

Model XG600 XG1200 XG1500

Pipe Diameter(mm) 300-600 800-1200 1000-1500

Pipe Length(mm) 2000 2000 2000

Motor power(Kw) 15 30 55

Model of Motor YCT225-4B YCT315-4A YCT355-4A

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Roller

Diameter(mm)

Ø140 Ø273 Ø325

RollerRotation

Speed

83-833(R/min) 69-687(R/min) 65-653(R/min)

3. Brief introduction of this machine

The Suspension Roller Concrete Pipe Production line includes: Pipe

machine, Pipe mould, concrete Feeder, concrete Mixer. The structure

of this pipe machine contains: Main Machine Frame, Roller, Movable

gantry frame, electric motor and driving machine.please refer to the

Appendix chart.

(1)Main Machine frame is used to install the motor, roller and driving

parts, it is the mainly supporting part of this machine, its structure is in

good design, and with good stability.

(2)Roller is the important part of this pipe machine, its function

contains the following three respect: A. It support the weight of pipe

mould and concrete; B. It drive the mould to rotate via the spacer;C. It

produces the roller force to the concrete in the mould.

(3)The function of the movable gantry is used to support the head of

the roller,and it can revolve horizontally, there will some fixed wedge

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pins to lock it when it is closed.

(4)The driving system is mainly used to control the rotation of the

roller, and provide the power to form the concrete pipes. It is made of

motor, pulley, roller,belt, bearing and bearing carrier.

(5)The pipe mould is including the mould body, spacer, bolts and

screws for closing the mould. According to different pipe joint, there

will be flush joint, groove joint, socket&spigot joint.

(6)The computer panel is used to control the electric motor, to finish its

electromagnetic control variable speed. There is Air-switch,Fuse,

Time-Relay in the panel, their function is short-circuit protection,

overload protection, open-phase protection.this panel is safe ,reliable

and easy to operate and repair.

(7)Concrete Feeder is an assistant machine that is designed for ease

worker's manual liability. It can delivery the mixed concrete in to the

mould evenly. It is made up by rotary drum, belt,guide pulley, machine

frame, driving motor.

4. Installation and trial production of the Suspension Roller Concrete

Pipe Machine

(1) Installation

A.We should consider electrical power,water,ground,water-proof,and

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transportation way before installation.

B.The ground for installation should be abroad and smooth,

Ground base should be substantial, the base hole is a little higher than

the ground in case flowing in to water.

C. There is drawing for the ground base in the appendix. Drug the

foundation base according to the drawing. The hole can be some bigger

and deeper.

D. Put two channel steel over the base hole,and use to crane to put the

machine frame and movable gantry on the channel steel, then put the

foundation bolts to the base of the machine,and screw the nut lightly,

but screw down it after you feed the cement.

E. Then lift the roller up, and fix it to the coupling shaft on the main

machine frame with bolts. At this moment, don't release the wire rope

on the roller,but put the roller to taper hole on the movable gantry, use

the gradienter to make the roller be horizontal.

F. Mix the concrete,and pour concrete into the base hole, and the

intensity of concrete should not be lower than C20, you should use the

vibrator to make it intensity ,there should be no air hole in the concrete.

(2) Preparation and inspection before trial production

A. In 4-5 days, the concrete is solid, then you can try operation.

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B. Use the gradienter to make sure the roller is horizontal or not, if

yes,then screw down the bolts on the coupling shaft, also check other

bolts having been screw down or not.

C. Check the electric power: rated voltage : 380 V, average error:10%.

D. Check the electric wire connection of motor and electric parts good

or not. Computer panel must be connected to the ground,its earth

resistance ≤4Ω.all the electric wires should be packed well, in case

they are destroyed or happening an accident.

E. Check the fixed taper on the movable gantry is locked well or not.

(3) Trial production with no load

A. After start the electric motor, the pointer of the motor should run by

deasil.

B. Adjust the speed at 1000 r/min with the regulator, the pipe machine

should be running stably without abnormal noise.

C. Then adjust the speed to the highest, the machine should be running

stably too, and the roller skip up less than 1mm.

(4) Trial production with full load

Following by the 《Techniques of the Operation》to try production.

During the expiration,if anything is abnormal, you should stop the

machine right away and check up it, settle the breakdown. Then try to

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start and operate it again.

5. Techniques of the Operation

(1) Raw material

A. Cement should use the silicate cement,normal cement, slag silicate

cement that not less than 425#. The cement you buy should be with the

quality eligible certificate or inspection report that are provided by the

factory with production permit license. If you buy the packed cement,

there should be kind, number, manufacture factory, production date and

so on.

B. Sand should be in accordance with GB/T14684-93《sand for

construction》,its fineness modulus MX=2.3-3.0, the silt content is not

more than 3%.

C. Gravels or cobble stone, should be accordance with GB/T14685—

—93《gravels, cobble stone for construction》，and soft particle content

should be not more than 5%, acicular and flaky particle is not more

than 15%. The biggest diameter of stone is less than 1/3 of the pipe

wall thickness. Also smaller than 3/4 of the span of the latitude steel

wire. And the silt content of the stone also should be less than 1%.

D. It is allowed to mix admixture into concrete, and the performance of

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the concrete should pass the inspection, but forbidden to add chloride.

E. The water for mixture concrete should be in accordance with JCJ63

regulation.water must be clean, the water can't be used that with PH

value less than 4 or within organics such as oil, sugar,acids

F. Steel should use the normal cold-drawn low carbon steel wire or

hot-rolled low carbon steel wire rods. The steel should be in

accordance with GB343—82《General purpose low-carbon steel wire》

or GB701—91《Normal hot-rolled low-carbon steel coil》

(2) Concrete Mix Proportion

A. Concrete mix proportion for suspension roller pipe machine

Cement: sand: stone: water=1：1.76：2.64：0.36

B. The class of concrete intensity should be not less than C30, and not

less than C40 if the pipe for jacking.

C. Water cement ratio ,please keep the value between 0.27 and

0.37,usually keep 0.35. For the smaller diameter pipe, because of its

dead weight is light, and then the roller force is also small.so the water

cement ratio can be a little higher.

D. Sand proportion , generally we keep this value be 0.4, notice that:

the concrete mix proportion can be adjustable according the local

material, but the concrete intensity can't be lower than basic request.

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(3) Manufacture of the Steel Wire Cage

When the suspension roller type pipe machine is used to produce the

concrete pipe for water drainage, the steel wire cage should be

produced by rolling cage welding machine, also can use the manually

cage machine, but for manually , the cage should be up to specification

《GB50204》

A. The cage should be produced according to the drawing, the steel of

every cage should be not less its drawing 97%.

B. Check the steel wire strictly , please clean the oil stain and the big

rust.

C. Adjust the longitude wire diameter and the screw pitch.,then start

Latitude wire Longitude wire Screw wire specifi. item

Wire D. Cage D. pitch turns Wire D. length No. length No.

￠400×2000 ￠5 434 90 26 ￠5 1990 6

￠500×2000 ￠5 539 77 30 ￠5 1990 6

￠600×2000 ￠5 640 63 36 ￠5 1990 7

￠700×2000 ￠5 744 53 42 ￠5 1990 8

￠800×2000 ￠5 852 45 49 ￠5 1990 9

￠900×2000 ￠5 956 40 54 ￠5 1990 10

￠1000×2000 ￠5 1060 34 63 ￠5 1990 11

inner ￠5 1235 38 57 ￠5 1990 13 ￠

1200×2000 ourter ￠5 1345 77 30 ￠5 1990 14 130 40

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the cage welding machine to produce the reinforced cages. And notice

the quality of the cage when finished!

D. The regular cage size and request are as follows! Please refer to

List1, List2, List3, List4.

E. The cage should be welded well. And the welding spot should be

strong and without twist!

F. The requirement of the wire cage should be implement the structure

Drawing. List1 Class I manually cage

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List2 Class I welding cage

Latitude wire Longitude wire Screw wire spec. item Wire

D. Cage D. pitch turns

Wire D

length No. length No.

￠400×2000 ￠6 438 90 26 ￠6 1990 6 ￠500×2000 ￠6 540 77 30 ￠6 1990 6 ￠600×2000 ￠6 648 63 36 ￠6 1990 7 ￠700×2000 ￠6 756 56 40 ￠6 1990 8 ￠800×2000 ￠6 864 48 46 ￠6 1990 9 ￠900×2000 ￠6 972 42 52 ￠6 1990 11 ￠1000×2000 ￠6 1080 37 58 ￠6 1990 12

inner ￠6 1246 42 52 ￠6 1990 13 ￠1200×

2000 outer ￠6 1395 83 28 ￠6 1990 15

150 40

Latitude wire Longitude wire Screw wire specifi. item Wire D. Cage D. pitch turns Wire D length No. length No.

￠400×2000 ￠5 434 90 26 ￠5 1990 6 ￠500×2000 ￠5 539 77 30 ￠5 1990 6 ￠600×2000 ￠5 640 63 36 ￠5 1990 6 ￠700×2000 ￠5 744 53 42 ￠5 1990 6 ￠800×2000 ￠5 852 45 49 ￠5 1990 7 ￠900×2000 ￠5 956 40 54 ￠5 1990 8 ￠1000×2000 ￠5 1060 34 63 ￠5 1990 9

inner ￠5 1235 38 57 ￠5 1990 10 ￠

1200×2000 outer ￠5 1345 77 30 ￠5 1990 11

130 40

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List3 ClassⅡ manually cage

List4 Class Ⅱ welding cage

（4）Mixture the Concrete

A. The Mixing equipment must be in the charge of Someone，you must

check the material quality and weigher equipment,and add some oil to

start the concrete mixer.then pour into the material to mix.

B. According to the concrete mixture ratio, and weighing by turns from

sand, cement, stone. And sand weighing deviation is less than 2%, that

of cement is less than 1%, and sand's is less than 3%. Water's is less

than 1%. You should add another more 25kg cement for the first

mixture in every shift. When in reality operation, you have to regulate

the ration according the feedback of the suspension roller pipe machine

operator.

C. You can pour into the raw material after start the concrete mixing

machine. Then add water to mix, and the net mixing time should be

more than 50 seconds and less than 3 minutes . During the mixture,

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generally never to stop the concrete mixing machine.

D. If you produce cement pipe in winter, you should preheat the raw

materials, keep 15 to 20 centigrade of the sand and stone. But the

temperature of water should keep less than 60℃. Temperature of

mixed concrete should keep not lower than 10℃.

E. Should control the parking time of the mixed concrete. When Room

Temperature is higher than 20℃,the parking time should be

controlled within 1 hour. If R.T. is lower than 20℃, the parking time

should be controlled not over 90 minutes. If run over the regulated

parking time, you should add some more cement to mix again in

accordance with actual situation. But exception of the cement

additives.

F. Please get two teams of every shift as regulation,and notes date on

them.

G. The testing room should cooperate with the Weigher ,and

someone is responsible for inspection of the raw material, weighing ,

working efficiency, and mixing quality, and report it by records.

H. Do the clean work to concrete mixer, batching machine, weighing

equipment, and operating panel.

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(5) Forming the pipes

A. The machine operator should be responsible by someone special.

Before start the machine, he should check the suspension roller

machine, concrete feeding machine, electric equipments. Fixing the

bolts, feed lubrication to the machine.

B. Also check the pipe mould to the pipe machine, check weather the

joint bolts on the mould are fixed? Whether the wire cage in the mould

is up to standards. Then install the mould to the pipe machine.

C. open the movable gantry, hoist the pipe mould with crane to the

suspension roller. At this moment, the mould can't touch the roller.

D. Close the gantry and lock it, then low down the mould to roller

slowly. Take off the the hanger on the mould,then start the machine

when the crane leaves.

E. Test whether the quality of concrete is up to the quality standards.

Before starting the machine, feed the hopper with concrete fully, and

control strictly the parking time of the concrete in the hopper!

F. Start up the pipe machine and till the mould revolves at the speed to

feeding concrete, then start up the feeder to convey concrete into the

mould from the end to the other end continuously. To promise the

intensity of the pipe wall, you'd better make the wall over thickness

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2-5mm.

G. After finished feeding concrete, let the feeder out of the mould.

Clear of the concrete on the stop rings, then can improve the speed of

the machine. The technical parameter forming the pipes as following

list5, List6.

H. Finish the roller force, and wait till the mould stop revolving. Check

the wall of the pipe, whether the quality is up to standard. And remark

the date and shift on it. If any defects on the pipe, workers of the

present shift should repair it then can be hoist off the roller.

List5 Class I pipe parameter techniques

not

e

：

Ne

t

rolling time can be adjusted in accordance with the intensity the

concrete dry hardness.

SPEED OF MOULD（R/M） SPE. ITEM

SPEED VIA FEED Speed of roller

Net rolling time （min）

remark

￠400×2000 90 250 3

￠500×2000 85 230 3

￠600×2000 80 210 3

￠700×2000 75 185 4

￠800×2000 70 165 5

￠1000×2000 65 132 5

￠1200×2000 60 110 6

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List6 Class II pipe parameter techniques

note：

（1）all the parameter are for reference, the actual situation according

to the pipe plant.

(2）Net rolling time can be adjusted in accordance with the intensity

the concrete dry hardness.

H. Use the crane to hoist the finished pipe mould, let it leave the

roller ,and open the gantry, hoist the mould to the steam water tank.

I. When the finished moulds are put away in the tank, and notice

that don't put the big mould over the the small mould. And all stacked

moulds should be not higher than the tank mouth. And cover the tank

tightly.

J. The concrete that drop off from the mould during the feeding ,

SPEED OF MOULD（R/M） Pipe diameter item

SPEED VIA FEED Speed of roller

Net rolling time （min）

remarks

￠400×2000 90 250 5

￠500×2000 85 230 5

￠600×2000 80 210 5

￠700×2000 75 185 6

￠800×2000 70 165 6

￠1000×2000 65 132 7

￠1200×2000 60 110 7

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you can't use this concrete directly to the mould , should mix it again in

the mixer machine. Also feedback the quality of concrete to the mixing

operator.

(6) maintenance of the pipe by water steam

A. For the drainage pipes, you should get the notice of the steam curing

then cure the pipes within the mould according to the steam curing

regulation.

B. The steam curing regulation please refer to the List 7.

Heating-up℃ Constant temp℃ cooling pipeclass

管 径 mm index item 1

hour 2

hour 3

hour 4

hour 5

hour 6

hour 8 hour

Total （hour）

￠

400-800 40-45 60-65 80-85

80-85 95 +5

80-85 90 +5

1h 7

（1+3+2+1）

class I ￠

1000-1200

40-45 60-65 80-85 80-85 95+5

80-85 95+5

80-85 95+5

1h

8 （1+3+3+1）

￠

400-800 40-45 60-65 80-85

80-85 95+5

80-85 95+5

1h 7

（1+3+2+1) class

II ￠

1000-1200

40-45 60-65 80-85 80-85 95+5

80-85 95+5

80-85 95+5

1h

8 (1+3+3+1)

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Note：The steam regulation should be adjusted according to actual situation of the

temperature or in winter.

C. Specially-assigned people are responsible for steam maintenance;

steam temperature and time are controlled based on steam regulation.

Testing temperature, recording, and storing data every 30 mins.

D Formed pipe should be hoisted slightly to the steam tank; in

addition, wasted crosstie and tire should be filled up into the bottom of

the tank regularly. It is forbidden that bigger pipe moulds press smaller

pipe.

5. Demoulding process is according to lab regulation; removal of the

mould should be on time.

6. Steam tank should be sealed properly. Testing staff should be aware

of the water line, and filling up the tank when necessary.

7. When lifting and falling the pipe mould and cover, these staff and

crane operator should work closely in order to prevent incident.

8. Steam maintenance includes heating up, constant temperature,

cooling ( see the chart 7bove).

9. According to chart 7, in the constant temp section, 80-85℃ is the

max temp of portland ement and normal portlant cement .95+5℃ is

the max temp of slag cement. Cooling depends on the actual situation.

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10. If different pipe moulds are steamed, they should be steamed

according to the specification of pipe mould.

（VII）installation and demoulding

1. Based on lab concrete pressure notes, demouding and its

pressure depend on national standards( actual demouding

pressure >70% designed pressure.

2. Hoist steamed pipe mould to demouding section, then

release the screw bolts on both sides. Hoist the up half mould ,

and hoist the pipe and stop rings from down half mould.

3. During the process of demouding, protection measures, correct

demouding procedure, and hoisting methods should be used in prevent

damage to the pipe and appearance.

4. Clean up the pipe mould, joint and stop rings after demouding.

Paint the pipe mould, joint and stop rings with insulator

5. Put qualified wire cage into the mould; seal the up half mould

and strengthen the screw bolts symmetrically. The wire cage should fit

the blueprint and in the properly position.

6. Hoist the installed pipe mould to the appointed area and wait for

following procedure.

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(IX) repair and maintenance

1. If imperfect pipes are found and with in the range of

GB/T11836-1999, you should repair the pipes effectively.

Repairing materials should be in the similar color with

concrete. Viscosity should exceed pipe concrete pressure, and its

compression strength should not beneath pipe concrete pressure.

2. Watering the pipes within the yard is suitable when under 10 ℃

3. Maintained concrete pipes should put in appointed area according

to GB/T11836-1999

（X）Process Flow Chart of the Suspension Roller Pipe Machine

Please refer to appendix (IX) chart

6. Repair and maintenance of pipe machine

（I）Inspection pre-production

1.Test the stability of the machine before turn it on, and make sure

electronic gear is good.

2. Ensure the portable gantry is locked.

3. Assure foundation bolts and coupling are fasten, especially for

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new machine.

（II）Maintenance after every shift

1. Cleanse concrete on the roller and feeder with water.

2. Shut down the power and lock down the computer panel.

3. Lubricate the screw and connections.

（III）periodic inspection

1. Check the abrasion of the roller and V belt.

2. Strengthen connections of the motor and electric elements, and

check the A/C power.

3. Check the margin of the roller's abrasion.

4. Improve operation management and record operation log. When

continuously working in encountered, shifting log should be recorded.

5. Prevent the machine from erosion when not working for a long

time.

7. Notice and Direction

1. The power light turns on when the machine is connected.

2. In oder to prevent damage of the stone, people should not stand

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near the roller when operating.

3. When accelerating the speed regulator, it should be steady and

slow.

4. When feeding manually, worker should feed concrete

equally to avoid the vibration of the pipe mould.

5. When hoist the pipe mould out of the roller, the pipe mould

should be hoisted first, and then unscrew the bolt of the bearing seat.

Finally, unlock the portable gantry. Roller can not be pulled when the

mould is not weighted.

6. During the process of demouding, it is recommended that

protection methods ,correct discharge and hoisting mode are applied to

avoid damage to the pipe and its appearance.

7. The machine cannot be inspected and repaired during working.

8. One machine can only produce pipes which are regulative. It

is banned for the machine to overload to evade damage to the driving

system.

9. Be aware of the water volume, either too much or little water

will result in the failure of pipe production.

8. Frequent breakdown and troubleshooting

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No. Breakdown Cause Resolution

1 Adjustable speed motor overheat

1、low voltage 2、overload

Checking connection

2 Transmission shaft voice

Damaged tapered roller bearing

Replace bearing 32228 GB/T297

3 Excess frame vibration

Foundation bolt loosening

Tighten with spanner

4

AC contactor tremble, sparks between contactors struck

1. Low voltage 2. Line drop 3. Uneven contactors

Unable to operate, stop working and replacing, bolt power wire, closing up the power supply

5

AC contactor coils still pull in when power is off

1、damaged contactor 2、oil stains on contactors

1、replacement of new products 2、remove oil stains with alcohol

6 Serious abrasion of the suspension roller

Because of the abrasion between roller and stop ring of the mould

Electric welding, then planishing with grinding wheels or lathe machining

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Appendi（1）List of Wearing Parts

No. Code Name &Spec. Position in use QTY

Note

1 GB/T297 Tapered roller bearing 32228

Middle bearing seat

2

2 GB/T288 Self-aligning roller

bearing 22224 Roller taper

sleeve 1

3 GB/T276 Deep groove ball

bearing6224 Square bearing

seat 1

4 GB/T1154

4 -1997

V Belt C2900 Used for main transmission

5

5

6

XG1200

7 GB/T297 Tapered roller bearing32218

Hoisting bearing seat

2

8 GB/T288 Slef-aligning roller

bearing 22216 Gantry 1

9 GB/T1154

4 -1997

V Belt C2000 Used in main transmission

4

XG600

10

11

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(2)List of Electric Elements(XG600)

（

3）

Lis

t

of

El

ect

ric

El

No. Code Name Model&Spec pcs Note

1 Amperemeter 59L1--150/5A

1

2 Voltmeter 59L1--450V 1

3 buttons LAIP-11 2

4 Indicator lamp TUP380V 2

5 Air swithc DZ10-100/330

1

6 Thermal relay TR16B-120/3D

1

7 AC contactor CT10×60A 1

8 AC contactor CT10×100A 2

9 Mutual inductor LWK-150/5A

1

10 Time relay TST-3A 1

No. Code Name Model&Spec. PCS Note

1 amperemeter 59L1--150/5A 1

2 Voltmeter 59L1--450V 1

3 button LAIP-11 2

4 Indicator lamp TUP380V 2

5 Air switch DZ10-100/330 1

6 Thermal relay TR16B-120/3D

1

7 AC contactor CT10×60A 1

8 Mutual inductor LWK-150/5A 1

9 Combined switch 1

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ements(XG1200)

(4) Structure Diagram of XG600

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(5) Structure Diagram of XG1200

28

（6）Drawing for Groundwork of the machine XG600

（7）Drawing for Groundwork of the machine XG1200

29

（8）Process Flow Chart for Suspension Roller pipe machine

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1) The pipe internal diameter ：300-2400mm .the pipe

length :1000-5000mm

2) the motor power :15-90kw

3) this machine can make the pipe with steel or without steel.

4) the average efficiency is one section /10 minutes.

5) through steam or natural maintenance,make the shaped pipe up

to the standard intensity.

6) this machine is simple in operation ,rotates steadily,is reliable

and durable in use ,is low in fault rate.

7) The pipe can apply to deep well ,field iirigatiion,highway

culvert,draining off water of municipal administration,ect

It is exported to Africa, South America, Middle East ,Indian. Etc.