Tecnologia de vibração com sistema pokers acoplado a equipamentos

1. 1
CONCRETE MASS VIBRATION

2. 2
BH160 introduction
• Hydraulic pokers especially designed for dam,harbour projects,
waves breakers…
• Used as a set, assembled on a carrier (hydraulic excavator,
buldozer, frame…)
• ATLAS COPCO can supply the BH160 beams assembled on a
hydraulic beam
•Customized design for specific attachment
• Start-up and on-site assistance by ATLAS COPCO technicians
details Poker BH160
Diameter of vibrating element (mm) 155
Length of vibrating element (mm) 472
Length of rigid section (mm) 1145
standard length of the hose (mm) 2000
average frequency on load (rpm) 7500
Idling frequence** (mm) 2500
Oil consumption per poker (l/mn) 20
Maxi pressure on load (bars) 160
Centrifugal force on load (N) 20348
Amplitude (mm) 4,3
** Low idle speed adjusted locally as per weather site condition

3. 3
Detailled explanation of the Hydraulic Set
•An heavy duty alternative to the electric & pneumatic pokers for dam, dry docks, heavy foundation,
waves-breakers and all mass concrete vibration applications.
•Present on many dams around the world during the last years (three gorges dam in China, Karoun 3&4 dam in
Iran, Subansiri dam in India, break wavers in le Havre, France…) ATLAS COPCO has built a strong and
reliable products to satisfy the customer’s daily intensive concreting needs.
•ATLAS COPCO can supply the hydraulic pokers BH160 from poker alone to a set of 1 to 8 pokers connected
to an hydraulic beam assembled on a carrier (hydraulic excavator, bulldozer, frame…)
•ATLAS COPCO provides also start-up and on-site assistance, operation and maintenance training.
•ATLAS COPCO provides customized design for specific attachment to fit on any carrier brands.
•An Ultrasonic sensor detects the concrete and launches the high idle speed vibration.
•The hydraulic system is controlled by an integrated electronic system.
•The set is equipped with an Hydraulic +/- 90° rotation system to vibrate entirely the surface.
•Each poker attachment offers a Mechanical +/- 10° oscillation of the poker to avoid any damages in the
structure when the pokers goes inside the concrete.
•A foldable crutch under the hydraulic beam allows to pose the beam on the floor.
•As a standard, an Hydraulic pressure gauge per poker shows instantaneously if the poker is working in
good condition.
•The system control panel in the cabin can also be equipped with optional digital pressure meters.
•Depending on weather conditions, an hydraulic oil cooler can be installed on the excavator.
•As a complement, large pneumatic diameter poker AY87, 107 or 157 or electric poker AN90 can be
used to vibrate the edges and corners.

4. 4
CHOICE OF THE EXCAVATOR
Concreting Capacity numbers of pokers
Numbers of pokers  numbers of excavators + weight of each beam
Type of excavator  maximum lifting capacity (weight class)
Two possibilities:
1 – the customer chooses the excavator by himself
2 – The customer ask us to specify some possible excavators
We need to check:
- maximum flow of the excavator pressure variable pump (l/min)
- maximum rated power of the engine (hp)
- Type of excavator  maximum lifting capacity (weight class)
?

5. 5
VIBRATION CAPACITY
Hydraulic beam rotation system
Working zone of vibrators beam
Limit of vibration
Radius of effectiveness of pokers
Calculation of the vibrating capacity :
Volume to be vibrated = M
Periodicity in months = x
Daily hours of concreting = H
C = M / (H*30*X) (m3/hr)
Theoritical capacity of a BH160 = 45m3/hr
750 mm 750 mm 750 mm
720 mm 720 mm

6. 6
VIBRATION CYCLE
1 - The boom of the carrier goes down, the poker
vibrates slowly
2 - The ultrasonic sensor detects the concrete and starts the
high speed vibration
4 - The boom of the carrier goes up, the sensor
does not detect the concrete anymore, the poker
turns slowly.
3 - The boom of the carrier immerses the poker,
the concrete
Is vibrated for a certain perdiod.

7. 7
VIBRATION DEPTH
Wet concrete Max 60 cm
Dry concrete
When using the poker to spread the
concrete, be carefull that the poker does not
touch to the dry concrete below.
Broken plates

8. 8
VIBRATION CAPACITY
Vib. 1
ETC……
Vib.
5
Result :
•No good vibration strategy
•Loss of time
•Loss of productivity
•Loss of energy (fuel…)
•Lack of vibration in some places resulting concrete compaction and air voids left in concrete
•Over-vibration in some places resuting weak concrete
NOT GOOD

9. 9
VIBRATION CAPACITY
750 mm
Limit of vibration
Radius of effectiveness of pokers
Vib. 1
Vib. 4
Vib. 3
Vib. 2
ETC……
Vib.
5
Possible
positionning if
necessary
GOOD
Result :
•Good productivity
•Energy saving (fuel…)
•Good vibration with perfect concrete compaction
•No air voids left in concrete

10. 10
POKER BEAM HYDRAULIC DIAGRAM
Designation Unit Value
Average frequency in air (rpm) 8000
Average frequency in concrete (rpm) 7500
Idling frequency (rpm) 2500
Maxi system pressure on load (bars) 160
Normal poker pressure in concrete (bars) 110
Average centrifugal force on load (N) 20348
Amplitude (mm) 4.3
Poker Input flow (l/min) 18
Total system input flow (l/min) 144
Number of vibrators 8
Rotating system 90°
Max rotation motor flow l/min 20 to 30
Hydraulic poker motors
Individual poker flow
regulator (max. 18l/min)
Beam rotation motor
Flow regulator for
beam rotation motor
Electrovalve
Pressure regulator
and flow divider
Filter

11. 11
STANDARD PRESSURE GAUGE PANEL
Pressure gauge for each poker
•Low speed, pressure around 40 to 50 bars.
•High speed in air, pressure around 70 to 80
bars.
•High speed in concrete, pressure around 90
to 100 bars
Standard Hydraulic pressure gauges come
with the machine if the optional digital
pressure gauges are not ordered.
One std hydraulic pressure gauge for each
poker.
The pressure gauge are connected directly
on the individual poker flow regulators
aluminium block.
They are located on the hydraulic beam.

12. 12
Bypass switch to be
used if the ultrasonic
sensor is durty
STANDARD CONTROL PANEL
If this light is ON, change
the filter inside the beam
Don’t start high speed
until this light is OFF.
Joystick to rotate the beam
OFF button
ON button

13. 13
Bypass switch to be
used if the ultrasonic
sensor is durty
OPTIONAL PRESSURE GAUGE PANEL
If this light is ON, change
the filter inside the beam
Don’t start high speed
until this light is OFF.
Joystick to rotate the beam
OFF button
ON button
Pressure gauge for each poker
•Low speed, pressure around 40 to 50
bars.
•High speed in air, pressure around 70
to 80 bars.
•High speed in concrete, pressure
around 90 to 100 bars

14. 14
KAROUN 3 – DAM PROJECT - IRAN
Length of the vault : 800m
Elevation of the vault : 230m
Elevation above sea level : 1032m
Four turbines of 250 MW each (263MVa each)
Three inlets for the turbines of 171m3/s
Lake length : 41km
Lake surface : 29.23 km²
Volume of reservoir : 2.1 Bm3
Concreting capacity : 60000m3 / month
Total volume of concrete : 3.6M m3
Finalization of project : 5 years
Karoun
3
after
elevation

15. 15
VIBRATION
Concrete before vibration
Concrete caracteristics:
Earth moist concrete (Slump : 0cm)
Max Size. Aggregate : 150 mm (ASTMC125 & ACI207.1R9to 11)
Aggregate : 0-5mm = 630Kg/m3
Aggregate : 5-10mm = 210Kg/m3
Aggregate : 10-30mm = 520Kg/m3
Aggregate : 30-60mm = 420Kg/m3
Aggregate : 60-120mm = 630Kg/m3
Cement content : 200Kg/m3
Concrete layer thickness : 50 – 60cm each
Water/cement Ratio : 0.5
Addition of Ice Cubes to slow down the chemical reaction (60kg/m3)
Concrete after vibration

16. 16
PICTURES OF THE SITE

17. 17
WAVE BREAKERS
Basically used for harbor dam
projects or river shores flooding
protection.
They are poured in specially made
formwork.
High production capacity.
Concrete blocks to be well vibrated
due to partial / full immersion in
salt/soft water.

18. 18
PNEUMATIC POKERS
In combination with hydraulic pokers, on a dam project, to prevent the formwork to
collapse, we recommend touse some pneumatic pokers (AY157) in order to vibrate the
edges of the lifts.
The pneumatic pokers have less power than the hydraulic ones, a one meter band has to
be vibrated handly.
In some cases, the contractor chooses to adapt on an independant air compressor located
on the excavator one or two pneumatic pokers.

19. 19