TWIN-LAYER PIPES

ES4037-080807-00 US
US 1
 TWIN-LAYER PIPES

A custom made
pipe system for your
concrete pump

ES4037-080807-01 US 2
 TWIN-LAYER PIPES

The Metric 148 mm 5 delivery system

Even though movement and flexing of the pipes of up to 2 deg. is possible,

the couplings will stay tight without leakage.

ES4037-080807-02 US 3
 TWIN-LAYER PIPES

The problem of Metric delivery lines,

with standard mild steel pipes.

Short service life of standard Uneven wear at inlet / outlet flanges

mild steel pipes. caused by the turbulences at the gap
Rock is harder than steel. and offset between the two pipes.

ES4037-080807-03 US 4
 TWIN-LAYER PIPES

Specific areas of high wear require special components

Wear at the outlet of the reducer. Wear at pivot points. Elbows installed at the end
of the boom in a descending
position are destroyed by
impact wear.

ES4037-080807-04 US 5
 TWIN-LAYER PIPES

Which essential qualities exist for Metric delivery lines?

Mild Steel Pipes

Pipes made of standard steel combined with cast elbows.
Easy to weld, only short service life, uneven wear.

Pipes with a modified chemistry of the steel

Cheaper pipes made of ST 37 as well, as more expensive tempered pipes for example,
do not improve the cost situation.

Single layer hardened pipes

Easy to weld, measuring of the wall thickness is possible from the outside.
Service life and costs are 2-3 times higher than mild stell pipes, which does not really
show an improvement in cost savings.

ES4037-080807-05 US 6
 TWIN-LAYER PIPES

Which essential qualities exist for Metric delivery lines?

Twin-Layer Pipes (ESSER TWIN PIPE 660)

Approx. 4-6 times more service life compared to mild steel pipes.
The welding and cutting of these pipes is only possible if special cooling is available.
The wear is still not exactly even.

Twin-Layer Pipes with Twin Cast Inserts (ESSER TWIN CAST 900)
With a special reinforcement and Twin Cast Elbows the most economical solution.
Approx. 8-10 times more service life compared to mild steel pipes.
Even wear within the entire delivery line.

ES4037-080807-06 US 7
 TWIN-LAYER PIPES

Boom Pipe Systems

ESSER TWIN PIPE 660 ESSER TWIN CAST 900

DN 125 4.8 (2.5+2.0 mm) DN 125 4.8 (3.0+1.5 mm)
Service life 4-6 times Hardened inner layer with a
compared to ST 52 plus. hardness up to 67 HRC.
Hardness up to 63 HRC. Service life 8-10 times compared
to ST 52 plus.

Depending on the design and the boom size wall thicknesses of 2.0+2.0 mm / 2.5+2.0 mm / 3.0+1.5 mm are available,
as well as an inner diameter of 125 mm (4.8), 117 mm (4.6), 112 mm (4.4).

ES4037-090303-07 US 8
 TWIN-LAYER PIPES

Deck Pipes and preferred Pipe Systems of up to 85 bar (1233psi) for

stationary concrete pumps

ESSER TWIN PIPE 660 ESSER PIPE TWIN CAST 900

DN 125 4.8 (5.6+3.0 mm)
Service life of 4-6 times
compared to ST 52 plus.
Hardness up to 63 HRC.
DN 125 4.8 (5.6+3.0 mm)
Hardened inner layer with a
hardness up to 67 HRC.
Service life 8-10 times compared
to ST 52 plus.

ES4037-080807-08 US 9
 TWIN-LAYER PIPES

Areas exposed to extreme wear

on pipe systems of concrete pumps

Area #1 + #2 Pivot Points

Area #3 First Deck Elbow

after Reducer

Area #4 Turret Elbow

Area #5 Impact Elbow

Area #6 Reducer

Area #7 Boom Cross-Over-Pipe

with Elbows of less than
90 deg. angle.

ES4037-080807-09 US 10
 TWIN-LAYER PIPES

Area #1 and #2 - Elbows at pivot points

Highest wear between the outlet of the first and the inlet of the second elbow.

The ESSER TWIN CAST 900 Elbows

with optimized Big Mouth flanges.

ESSER TWIN CAST 900

Elbow DN 125 - 4.8 x 90
TWIN CAST inner layer
wall thickness 7.0 mm.
Hardness up to 67 HRC.
Ultra wear resistant
Big Mouth TWIN CAST flange
at the inlet and outlet end.

ES4037-080807-10 US 11
 TWIN-LAYER PIPES

Area #3 First Deck Elbow after Reducer

Due to the velocity and turbulence of the concrete and the location of the first elbow after
the reducer, a special extremely wear resistant TWIN CAST Elbow is needed.

ESSER TWIN CAST 900

Elbow DN 125 - 4.8
Twin Cast inner layer
wall thickness 7.0 mm.
Hardness up to 67 HRC.
Ultra wear resistant
Big Mouth TWIN CAST flange
at the inlet and outlet end.

ES4037-080807-11 US 12
 TWIN-LAYER PIPES

Area #4 Turret Elbow

Due to the velocity of the concrete and the frequent stroke changes of the concrete pump,
an impact situation is created within the 90 degree bottom elbow of the turret.

ESSER TWIN CAST 900

Turret Elbow DN 125 - 4.8 x 90
Ultra wear-resistant
TWIN CAST Big Mouth inlet / outlet
flanges.
Service life 8-10 times compared
to common cast elbows.

ES4037-080807-12 US 13
 TWIN-LAYER PIPES

Area #5 Impact Elbow

The IMPACT ELBOW is the next to last elbow at the end of the boom and exposed to
extremely high wear. In most pumping applications the descending
position of the last boom section allows the concrete to fall into the
next to last elbow causing ultra high impact wear.

ESSER TWIN CAST 900

Impact Elbow DN 125 - 4.8 x 90
The Esser TWIN CAST 900 impact elbow is
designed with a 12 mm ultra wear and impact
resistant cast inner liner.
Hardness up to 67 HRC.
Areas exposed to extreme wear are protected
by the Big Mouth TWIN CAST flanges.
The impact elbow delivers 8-10 times longer
service life than a conventional cast iron elbow.

ES4037-080807-13 US 14
 TWIN-LAYER PIPES

Area #6 Reducer
Reducers create a higher velocity towards the outlet end and cause an increase of pressure
in the concrete flow. Especially the ESSER 900 Reducers have been improved
at the critical areas.

ESSER TWIN Standard Reducer 780

DN 150-125 (6.0-4.8)
Highly wear resistant wear rings in
the inlet flange.
Manufactured from laminated steel.
Hardness up to 63 HRC.
Wall thickness 4.0+4.0 mm

ESSER TWIN CAST 900 Reducer

DN 150-125 (6.0-4.8)
Pressure resistant outer shell.
Ultra wear resistant TWIN CAST
inner layer.
Special TWIN CAST wear rings at
inlet and outlet flanges.
Hardness up to 67 HRC.

ES4037-090303-14 US 15
 TWIN-LAYER PIPES

Area #7 - Boom Cross Over Pipe and Elbows TWIN CAST 900

Standard New improved

ESSER TWIN CAST 900 ESSER TWIN CAST 900
Big Mouth XL
The specifics of long booms in most cases
require Cross-Over-Pipes that are fixed
between two 45 deg. (or less) Elbows.
The velocity, turbulence and diversion of
the concrete causes extreme wear in the
inlet of the Cross-Over-Pipe after the
elbow. The improved design with Big Mouth
XL flanges will increase service
life by approx. 50%.

Please note:
For improved service
life pipes and elbows
should be rotated
according to the
service information

ES4037-080807-15 US 16
 TWIN-LAYER PIPES

Areas exposed to extreme wear

on pipe systems of C-Valve concrete pumps
Area #1 + #2 Pivot Points

Area #3 First Deck Elbow

after Reducer

Area #4 Turret Elbow

Area #5 Impact Elbow

Area #6 Reducer (short, only

on C-Valve machines)

Area #7 Boom Cross Over Pipe

with Elbows of less than
90 deg. angle.

Area #8 Pressure Pipe (only

on C-Valve machines)

ES4037-080807-16 US 17
 TWIN-LAYER PIPES

Area #6 Reducer on C-Valve Machines

Reducers create a higher velocity towards the outlet end and cause an increase of pressure
in the concrete flow. Especially the ESSER 900 Reducers have been improved
at the critical areas.

ESSER TWIN Reducer 800

DN 137-125 (5.4-4.8)
Highly wear resistant cast insert in the
inlet flange.
Manufactured from laminated steel.
Hardness up to 63 HRC.
Wall thickness 4.0+4.0 mm.

ESSER TWIN CAST 900 Reducer

DN 137-125 (5.4-4.8)
Pressure resistant outer shell.
Ultra wear resistant TWIN CAST
inner layer.
Special TWIN CAST wear rings at
inlet and outlet flanges.
Hardness up to 67 HRC.
Wall thickness of inner layer 7.0 mm.

ES4037-080807-17 US 18
 TWIN-LAYER PIPES

Area #8 Pressure Pipe on C-Valve Machines

Pressure Pipes are exposed to extreme wear due to the high pressure close to the
conveying pistons.

ESSER TWIN Layer Pressure Pipe DN 137 ( 5.4)

Hardness up to 63 HRC.
Wall thickness inner layer 5.6 mm.
Ultra wear resistant TWIN CAST ring implemented in inlet flange.

ES4037-080807-18 US 19
 TWIN-LAYER PIPES

ES4037-080807-19 US 20
 TWIN-LAYER PIPES

Advantages of using Twin-Layer Pipes

ESSER 900: Service life of 8-10 times compared to ST 52

ESSER 660: Service life of 4-6 times compared to ST 52

ESSER 500: Service life of 2-3 times compared to ST 52

Less down time of the concrete pump caused by pipe replacement

Excellent cost/performance ratio

High profitability

Controlled work shop costs

ES4037-090303-20 US 21
 TWIN-LAYER PIPES

Comparison
ADVANTAGES DISADVANTAGES

: Short service life and low protection

; Easy to weld.
Standard Mild ; Measuring of wall thickness from the outside.
against break down.
Steel ST52 : High costs for pipe exchange.
; Low purchasing costs.
: Extensive down time of the machine.

; Durability 2-3 times compared to ST 52.
;
ESSER 500 Lower pipe installation costs and less down time
of the machine.
; Improved cost / pumping ratio compared to ST 52.
: Welding of pipes is only possible with a special
cooling system.
: Measurement of wall thickness is only possible
with the pipeline opened up.

; Durability 4-6 times compared to ST 52.
;
ESSER 660 Lower pipe installation costs and less down time
of the machine.
; Improved cost / pumping ratio compared to ST 52.
: Welding of pipes is only possible with a special
cooling system.
: Measurement of wall thickness is only possible
with the pipeline opened up.

; Durability 8-10 times compared to ST 52. : Welding of pipes is only possible with a special
;
ESSER 900 Lowest cost on pipe installation and downtime cooling system.
costs. : Measurement of wall thickness is only possible
; Lowest cost ratio per cu.yd. of concrete pumped. with the pipeline opened up.

ES4037-090303-21 US 22
 TWIN-LAYER PIPES

Cost Comparison (Example: Boom)

80

ST52

70

60

CF U3
50
Costs in 1.000 USD

ESSER 500
40

ESSER 660

30
ESSER 900

20

10

0
0 10.000 20.000 30.000 40.000 50.000 60.000 70.000 80.000 90.000 100.000 110.000

Concrete pumped in cu.yds.

ES4037-090113-22 US 23
 TWIN-LAYER PIPES

Cost Comparison (Example: Boom)

Quality ST 52 Conforms U3 ESSER 500 ESSER 660 ESSER 900

Wall thickness 4 mm 4,9 mm 2,5 + 2 mm 2,5 + 2 mm 3,0 + 1,5 mm

SINGLE SINGLE TWIN TWIN
Type of Pipe TWIN LAYER
LAYER LAYER LAYER LAYER

Price per Pipe

$4.275,00 $5.893,86 $6.580,00 $8.490,00 $11.600,00
System complete

Labor Cost per Pipe

2 Men 6,0 h $55,00 $660,00 $660,00 $660,00 $660,00 $660,00
Change

Loss of Revenue
$1.500,00 $1.500,00 $1.500,00 $1.500,00 $1.500,00
based on Downtime

Interest per year 6% $256,50 $353,63 $394,80 $509,40 $696,00

Service Life of Pipe 10.000 20.000 25.000 50.000 100.000

System cu.yds. cu.yds. cu.yds. cu.yds. cu.yds.

Costs per cu.yds.

$0,67 $0,42 $0,37 $0,22 $0,14
pumped

Investment for Parts

up to 100.000 $66.915,00 $42.037,46 $36.539,20 $22.318,80 $14.456,00
cu.yds.

Effective costs could be higher because of different down times

and installation times. (statement without obligation)

ES4037-090303-23 US 24
 TWIN-LAYER PIPES

ES4037-080807-24 US 25
 TWIN-LAYER PIPES

Pipes are worn by

concrete abrasion.

ESSER TWIN PIPES provide

the lowest wear factor and
the highest cost efficiency.

ES4037-080807-25 US 26
 TWIN-LAYER PIPES

Reasons for wear on delivery pipe systems

Flow rate of concrete (cu.yd./h)

Hardness of the sand and aggregate to be pumped

Shape and size of aggregate

Consistency and mix design of the concrete

I.D. of the Pipe System

Location of the individual pipe component within the system

Pressure of concrete inside the delivery line

ES4037-080807-26 US 27
 TWIN-LAYER PIPES

The
The following
following corrective
corrective
actions
actions will
will increase
increase
the
the service
service life
life
of
of the
the pipe
pipe system.
system.

ES4037-080807-29 US 28
 TWIN-LAYER PIPES

Increase the service life

Problem:
One sided wear on pipes and elbows.

Corrective Action:
After 15-20% of the expected service life pipes should be
rotated horizontally by approx. 120 degrees.
After approx. 50% of the expected life the straight pipes
should be turned end for end by 180 degrees.
The elbows should be turned end for end by 180 degrees
also.

ES4037-080807-30 US 29
 TWIN-LAYER PIPES

Excessive Wear on Cross-Over-Pipe TWIN CAST 900

Problem:
The straight Cross-Over-Boom pipe
shows premature wear.

Possible causes:
High velocity and turbulence of the
concrete after a small short radius elbow
causes the Dish-Out in the following
straight pipe.

Corrective Action:
Straight pipes with Big Mouth XL inlet
flanges should be installed after small
elbows.
Generally the straight pipes
should be rotated.

ES4037-080807-31 US 30
 TWIN-LAYER PIPES

Abnormal wear of Elbows in Impact Position

Cause:
1 = Z-Fold
In most pumping applications the descending position of 2 = Roll-Fold
the last boom section allows the concrete to fall into the 3 = Uneasy Position
next to the tip elbow causing ultra high impact wear.
Working in position 3 will allow the concrete to free fall at
high velocity and cause high impact wear.
3

2
Corrective Action:
The boom should be fitted with a true Impact
Elbow. (ESSER Part. # 1-0120-292-0100-00)
Service life will be 8-10 times longer than 1
regular cast elbows.
Boom should be operated in working position 1
or 2, if possible to prevent the concrete from free
falling.
ES4037-090303-32 US 31
 TWIN-LAYER PIPES

Premature wear underneath the pipe bracket (sometimes just in one spot)

Possible causes:
Stone or dirt between pipe and bracket can cause
indentation of pipe when bracket is tightened.
Tightening of bracket without a torque wrench, may
cause damage of hardened inner liner.

Corrective Action:
Torquing force of 40 Nm (approx. 30 lbs.ft) must not be
exceeded.
Pipe and bracket must be absolutely clean prior to the
assembly.
Pipe brackets must be inspected prior to assembly.

ES4037-080807-33 US 32
 TWIN-LAYER PIPES

Damaged boom pipe under pipe bracket

Picture from inside of a damaged pipe.

Hole under the boom bracket as a piece of the layer has

broken out.

ES4037-080807-34 US 33
 TWIN-LAYER PIPES

Wear pattern of TWIN CAST Elbows

Problem:
Elbow inlet of TWIN CAST Elbows
seems to be worn out.

Retaining lip of the

TWIN CAST wear ring
leaves the impression
of total wear at the
inlet.

Reality:
Even though it looks that the inlet of the
elbow is worn out completely there is still
a inner liner thickness of 1 mm left,
enough for pumping 5.000 7.000 m
(6,540 9,156 cu.yds.) additional.

ES4037-080807-35 US 34
 TWIN-LAYER PIPES

Wear pattern of TWIN CAST Elbows

Old Design New Design

Retaining lip Big Mouth flange with

better wear indication

When the inner liner is worn down to the retaining lip, there is still further life left (Covered by the retaining lip).
Further usage is possible. In this situation the Elbow should be turned around (END for END). The wall
thickness of the flange inside the groove for the coupling should be measured.

ES4037-080807-36 US 35
 TWIN-LAYER PIPES

Measurement of wall thickness of elbows

(to evaluate the future date of exchange)

Exact adjustment of
probe tips at P1 and P2

ESSER TWIN PIPE 660

Dia.: DN 125
Quality: 660
Wall thickness: 7.1+3.6

Wall thickness at
P1 P2
measuring points
Wall thickness
Approx. 8.2 mm Approx. 8.2 mm
Suggested exchange

Based on raw material tolerances, nominal wall thicknesses may slightly vary.

ES4037-090113-37 US 36
 TWIN-LAYER PIPES

Measurement of wall thickness of elbows

(to evaluate the future date of exchange)

Exact adjustment of
probe tips at P1 and P2

ESSER TWIN CAST 900

Dia.: DN 125
Quality: 900
Wall thickness: 7.0+2.0

Wall thickness at
P1 P2
measuring points
Wall thickness
Approx. 8.8 mm Approx. 8.8 mm
Suggested exchange

Based on raw material tolerances, nominal wall thicknesses may slightly vary.

ES4037-090113-38 US 37
 TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

Exact adjustment of
probe tips at P2

ESSER TWIN PIPE 500

Dia.: DN 125
Quality: 500
Wall thickness: 2.5+2.0

Wall thickness at
P1 P2
measuring points
Wall thickness
Approx. 2.8 mm Approx. 8.8 mm
Suggested exchange
Based on raw material tolerances, nominal wall thicknesses may slightly vary.

ES4037-090303-41 US 38
 TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

Exact adjustment of
probe tips at P2

ESSER TWIN PIPE 660

Dia.: DN 125
Quality: 660
Wall thickness: 2.5+2.0

Wall thickness at
P1 P2
measuring points
Wall thickness
Approx. 2.8 mm Approx. 8.3 mm
Suggested exchange

Based on raw material tolerances, nominal wall thicknesses may slightly vary.

ES4037-090113-39 US 39
 TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

Exact adjustment of
probe tips at P2

ESSER TWIN CAST 900

Dia.: DN 125
Quality: 900
Wall thickness: 3.0+1.5

Wall thickness at
P1 P2
measuring points
Wall thickness
Approx. 2.4 mm Approx. 8.8 mm
Suggested exchange
Based on raw material tolerances, nominal wall thicknesses may slightly vary.

ES4037-090303-40 US 40
 TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

Exact adjustment of
probe tips at P2

ESSER TWIN PIPE 660

Dia.: DN 125
Quality: 660
Wall thickness: 5.6+3.0

Wall thickness at
P1 P2
measuring points
Wall thickness
Approx. 4.0 mm Approx. 8.3 mm
Suggested exchange
Based on raw material tolerances, nominal wall thicknesses may slightly vary.

ES4037-080807-41 US 41
 TWIN-LAYER PIPES

Measurement of wall thickness of pipes

(to evaluate the future date of exchange)

Exact adjustment of
probe tips at P2

ESSER TWIN CAST 900

Dia.: DN 125
Quality: 900
Wall thickness: 5.6+3.0

Wall thickness at
P1 P2
measuring points
Wall thickness
Approx. 4.1 mm Approx. 8.8 mm
Suggested exchange
Based on raw material tolerances, nominal wall thicknesses may slightly vary.

ES4037-080807-42 US 42
 TWIN-LAYER PIPES

Contact

ESSER TWIN PIPES LLC.

147 Airpark Industrial Road
Alabaster, AL 35007
USA
Tel. +1 (205) 621 2454
Fax +1 (205) 621 9739
Web www.esserllc.com

ESSER TWIN PIPES LLC. LTB Le Tuyau Bi Metal ESSER-WERKE GmbH & Co. KG ESSER TWIN PIPES Shanghai Office ESSER NIPPON CO., Ltd.
2700 Wisconsin Street 13 Avenue de l'Europe Zum Puddelhammer 25 Room C. 24 F - No. 728 Xi Zang Middle Rd. 1 - 3 Okayamada, Togane-shi
Sturtevant, WI 53177 67300 Schiltigheim 59581 Warstein 200001 Shanghai 283-0826 Chiba
USA FRANKREICH DEUTSCHLAND CHINA JAPAN
Tel. +1 (262) 884 8805 Tel. +33 (388) 564 500 Tel. +49 (2902) 896 0 Tel. +86 (21) 530 866 60 Tel. +81 (0) 475 53 4433
Fax +1 (262) 884 8803 Fax +33 (388) 564 711 Fax +49 (2902) 896 30 Fax +86 (21) 530 866 61 E-Mail m.egami@esser.co.jp
Web www.esserllc.com E-Mail france@essertwinpipes.com E-Mail info@esser-werke.de E-Mail china@essertwinpipes.com Web www.essertwinpipes.com
Web www.essertwinpipes.com Web www.esser-werke.de Web www.essertwinpipes.com

ES4037-080807-64 US 43