Signal loss on a concrete line pump wireless remote control system poses several risks that can affect safety, operational efficiency and potentially the quality of concrete being pumped.

Compromised quality of concrete

Signal loss from the handheld remote to the truck/trailer side receiver leads to interruptions in the concrete pumping process. These delays can potentially compromise the quality of the concrete being pumpe​d in several ways:

• Inconsistent Flow: Dropped signals and the resulting interruptions can lead to inconsistent flow of concrete, causing segregation or the separation of aggregate from the cement paste. This affects the uniformity and strength of the concrete once se​t.

• Slump Loss: Repeated starts and stops may accelerate slump loss, changing the concrete's workability and potentially requiring additional water or admixtures to correct the slump, which can weaken the concret​e.

• Air Entrainment: Interruptions might affect the air content, as the pumping process can entrap air in the concrete mix, leading to reduced durability and strength if not properly manage​​d.

• Cold Joints Formation: Delays caused by signal loss can lead to the formation of cold joints between layers of concrete, compromising the structural integrity and leading to potential points of weakness.

Safety Hazards

If a remote loses its connection to the equipment it is controlling, there is an increased risk of accidents. Signal loss between a remote control and the concrete line pump can lead to several safety hazards:

• Uncontrolled Operation: If signal loss occurs, the pump may continue to operate uncontrollably or stop unexpectedly, posing a risk to nearby workers and potentially leading to accidents​.

• Hose Whipping: Interruptions in pumping caused by signal loss can introduce air into the placing lines, leading to hose whipping. This is a dangerous condition where the hose violently whips around, potentially causing injury to worker​​s.

• Electric Shock: In the event of uncontrolled boom pump operations, the machinery could come into contact with power lines, especially if the pump is operating near them. This could lead to electric shock hazards due to the high water content in concret​​e.

Equipment Damage

Unintended operation or sudden shutdowns due to signal loss can cause mechanical stress or damage to the pump, leading to costly repairs or downtim​​e. Signal loss can cause mechanical stress or damage to the pump in several ways:

• Pressure Fluctuations: Sudden stops and starts can create pressure surges within the pumping system. These fluctuations can stress the pump's mechanical components, leading to wear or failure over time.

• Material Settling or Blockage: Interruptions in the flow of concrete can allow the material to start setting within the pump or lines. This can result in blockages that are difficult to clear and may cause mechanical stress or damage when attempting to restart the pump.

• Component Wear: The start-stop nature of operations due to signal loss increases the frequency of cycles the components are subjected to, accelerating wear and reducing the lifespan of seals, bearings, and other critical part​​s.

Inconsistent Concrete Placement

Signal loss may result in inconsistent or incorrect placement of concrete, affecting the structural integrity of the construction project and leading to additional work to correct the error. Specifically:

• Interruptions in Flow: Signal loss can cause sudden starts and stops in the pumping process, leading to interruptions in the flow of concrete. This can result in areas of the pour being too thin or too thick, compromising the structural integrity.

• Variability in Pump Pressure: Without consistent control, the pump may operate at variable pressures, leading to inconsistencies in the volume of concrete placed. Higher pressure can cause excessive concrete to be delivered, while lower pressure might not deliver enough concrete to the intended area.

• Compromised Timing and Coordination: The timing and coordination of concrete pours are crucial for achieving uniformity and structural integrity. Signal loss disrupts the precise control over the pumping, potentially leading to premature setting of some concrete sections before other sections are poured, creating weak point​​s.

These disruptions not only affect the quality of the concrete placement but can also lead to additional labor and material costs to correct the inconsistencies and ensure structural safety. For some concrete pumping companies, this could also risk the working relationship with the general contractor.  

Summary

A remote control that consistently drops its signal connection to the concrete line pump introduces risk of operational inefficiencies, compromised concrete, worker safety concerns and potential equipment damage. These issues highlight the importance of reliable remote control systems for concrete line pumps to ensure continuous, controlled pumping for optimal operations, safety and concrete quality.

Check out our blog post on factors that impact a remote’s signal and what to look for to ensure worry free, long range operations and all the benefits of wireless remote machine control at range.