More than just a catch phrase, preventative maintenance supplies pump owners with several benefits including safety, reliability on the job site, higher resale value, and priceless peace of mind. Pumping contractors across the country are recognizing the importance of installing rigorous programs to protect their livelihood. <\/p>\n
Jeff Popa, Service Manager at Schwing America\u2019s White Bear, MN headquarters, says several factors contribute to the growing importance and popularity of stringent preventative maintenance programs. \u201cAdvancing technology has prompted some pump owners to pay closer attention to their programs,\u201d says Kline. \u201cThe technology is reliable but complicated, and all of the components require routine inspection. Contractors are also placing higher demands on their concrete pumps \u2013 tougher mixes, longer pours. The more wear and tear, the more often these practices should be implemented.\u201d <\/p>\n
Lou Murray, Concrete Placement Manager with Meyer Materials Co., Des Plaines, IL, and Randy Waterman, Phoenix Branch Manager for Brundage-Bone Concrete Pumping, oversee preventative maintenance programs for their companies. The two provided details on their regimented operations. <\/p>\n
First and foremost, both agreed on the importance of the one-operator-per-machine rule. \u201cYou can\u2019t put a value on assigning one specific operator to one specific pump,\u201d says Murray. \u201cOur operators are with their machine sometimes ten to 14 hours a day. They are familiar with all of the idiosyncrasies that accompany that particular pump. For instance, our operators are the most qualified to diagnose a particular noise as a serious problem, and they are familiar enough to know if it\u2019s simply the way the pump performs.\u201d<\/p>\n
Both companies keep tabs on preventative maintenance programs through requiring extensive paperwork from their operators and maintenance crews. Meyer Materials has implemented a process for three categories; boom pipe thickness, truck tire maintenance, engine and pump service are all carefully documented according to Lou Murray\u2019s guidelines. Major service and maintenance needs, particularly those outsourced, are also carefully documented. <\/p>\n
\u201cIt\u2019s almost like the military when I talk about it,\u201d says Brundage-Bone\u2019s Randy Waterman. \u201cTheir maintenance checklists aren\u2019t just suggestions, they\u2019re requirements. They have to turn in their punch-lists and pick up literature on safety and other policy notices before they receive their paychecks. For one thing, state law enforces daily DOT inspections. The pumps have to meet state standards before they even hit the job, and for the most part, the operator is responsible for the condition of the pump. It\u2019s not only a company concern, it\u2019s a matter of personal responsibility.\u201d Brundage-Bone\u2019s Phoenix Branch Maintenance Supervisor is responsible for collecting data and keeping updated records on each operator and each pump. <\/p>\n
Both contractors require completed paperwork on specific areas on the boom pump and truck. Meyer Materials crews inspect all aspects of the hydraulic system once every month as part of their routine maintenance checklist. The company also requires regular use of filter carts, instruments used to filter new hydraulic fluid and condition fluid already in use. Murray explains why the company implements the use of filter carts once a year. \u201cClean hydraulic oil means a healthy hydraulic pump. Filtering new oil ensures there is no contamination right out of the drum. It\u2019s peace of mind.\u201d <\/p>\n
Brundage-Bone\u2019s Randy Waterman says the company\u2019s routine maintenance program requires that crews replace the motor oil every three hundred operating hours. Crews utilize filter carts to filter hydraulic oil each time the oil is replaced. \u201cI could never really qualify it with a number, but the filter carts have certainly provided an extended life for the hydraulic pumps.\u201d <\/p>\n
Jerry Anderson, General Manager of Concrete Pump Repair (CPR), runs a tight ship at the Schwing-certified parts and service center in North Branch, MN. Anderson says filtering or changing out the hydraulic fluid is one of the most important aspects of pump maintenance. \u201cI\u2019d recommend oil change-out, tank clean-out and filter use once a year at minimum.\u201d <\/p>\n
Anderson also says maintenance to the pumps electrical system is an important component to pump performance and life span. \u201cWhen it comes the electrical system, there should be no quick fixes. A thorough inspection is absolutely vital \u2013 bypassing any type of potential problem poses serious threat to the pump\u2019s performance.\u201d <\/p>\n
Boom pipe maintenance is another obvious consideration for both contractors. When it comes to inspecting the wear and tear on a pipe, Meyer Materials depends on ultrasonic technology. <\/p>\n
\u201cA while ago, you\u2019d use the old-school system to inspect the boom pipe for deficiencies. Walk up, tap on the pipe. You might have heard something that indicated the pipe was thin, and you might switch it out. We invested in an ultrasonic gauge to inspect boom pipe wear. Now we\u2019ve got the technology to thoroughly inspect the pipe on a regular basis without the guesswork,\u201d says Murray. <\/p>\n
Meyer\u2019s operators are supplied with standardized sheets to ensure every feature of the boom is inspected for wear. As an extra precaution, Meyer changes out their fleet\u2019s boom pipes based on yardage. <\/p>\n
Brundage-Bone\u2019s crews flip and rotate boom pipes at certain pre-determined points in the pipe\u2019s life. \u201cThe main objective behind boom pipe maintenance is to utilize the pipe to its full life without getting greedy. We chart yardage and flip and rotate the boom pipe when it\u2019s one-third and two-thirds into its typical life span. And we make sure we\u2019re not being too optimistic about wear and tear,\u201d says Waterman. Once it reaches the end of its pre-determined life cycle, crews replace the pipe. <\/p>\n
Brundage-Bone also executes elbow rotation at the same time they inspect boom pipes for wear. \u201cIt\u2019s an important step in PM,\u201d says Waterman. \u201cIt has certainly allowed us a 20% elbow life increase.\u201d <\/p>\n
Meyer Materials also practices elbow rotation on a regular basis. \u201cWe use our ultrasonic gauge to inspect the elbows as well. We don\u2019t let it get to a point where we\u2019re throwing out a pipe prematurely, but we\u2019re very careful. We keep the elbows marked and rotate them before there\u2019s any extensive wear. We also inspect the gaskets and change them out routinely.\u201d<\/p>\n
\u201cWe\u2019re regularly checking our Rock Valve wear parts. Particularly during our slow months in January and February, we make sure we do a thorough check of everything \u2013 seals, bushings, cuttings – and we make sure the rings are greased.\u201d <\/p>\n
Inspection of Rock Valve wear parts is on the weekly schedule for Brundage-Bone crews. \u201cIt\u2019s part of being an operator,\u201d said Waterman. \u201cWear part inspection is one of their top priorities.\u201d<\/p>\n
As part of their strict maintenance regimens, Meyer Materials and Brundage-Bone make sure boom inspections are executed regularly. While Meyer out-sources their boom inspection and repair services, Brundage-Bone boom pumps are sent to the company\u2019s own rebuild facility in Seattle, WA. \u201cWe\u2019ve got an in-house Schwing-certified serviceman and inspector who completes the inspections and repairs that he deems necessary,\u201d says Waterman. <\/p>\n
CPR\u2019s Jerry Anderson says boom inspections should be executed based on age: pumps from one to five years old should be inspected at least once a year; pumps five to ten years old should be inspected once every six months, and pumps above ten years old should be inspected every 500 operating hours. DOT inspections should be conducted once a year. \u201cIn the interest of safety, performance and pump life, any recommended repairs should be done immediately following these inspections.\u201d CPR employs four boom inspectors and four welders to execute required repairs.<\/p>\n
To prevent costly repairs for problems diagnosed during boom inspections, the contractors make sure that all moveable boom parts remain properly greased.<\/p>\n
\u201cWe have autogreasers on all of our larger boom pumps, and those are checked regularly and maintained to a standard. Our operators make sure that the smaller booms stay manually greased,\u201d says Meyer Material\u2019s Lou Murray.<\/p>\n
Waterman says that the newer boom pumps within Brundage-Bone\u2019s fleet are equipped with autogreasers, and operators are responsible for maintaining their performance as well. Operators assigned older models execute strict weekly greasing schedules. <\/p>\n
CPR\u2019s Jerry Anderson says that auto-greasers are a viable addition to a standard concrete pump. \u201cIdeally, the boom should be greased once a week, and the back end should be greased after each and every pour,\u201d says Anderson. \u201cAutogreasers have to be carefully maintained, and movable parts should be checked constantly to ensure proper greasing.\u201d <\/p>\n
Truck maintenance is also an important consideration in regular PM programs. \u201cOur own mechanics practice the 300-hour rule for oil changes and filters. Larger, more extensive maintenance or service is outsourced. We\u2019re very careful with our tire maintenance. Before Meyer implemented a monthly system, we were running into problems with the manufacturer. Now, we make sure to consistently check the air pressure and keep detailed monthly records of tire maintenance,\u201d says Murray.<\/p>\n
Brundage-Bone takes boom truck maintenance just as seriously. \u201cOur entire company also operates by the 300-hour rule,\u201d says Waterman. Tires are checked and rotated by the tire manufacturer every month, and Brundage-Bone follows their recommendations when it comes to replacement. <\/p>\n
All 30 Brundage-Bone locations utilize the same vendors for consumables such as tires, filters, and hydraulic oil. \u201cIt makes sense from a financial standpoint,\u201d says Waterman. \u201cBut it also allows all of us to communicate about the best way to handle PM practices and scheduling. Establishing a relationship with a vendor is also important \u2013 they have a vested interest in providing you with the best parts and the best advice for maintenance.\u201d<\/p>\n
Climate also has an effect on contractors\u2019 PM programs. With headquarters in the northern Midwest, Meyer takes the winters seriously. \u201cWe keep the pumps in a heated shed year round to protect them from the elements. When it comes to the coldest of cold – and we\u2019ve got it in Illinois – we follow the manufacturer\u2019s recommendations to a tee to ensure we can keep up with production requirements without endangering the pump.\u201d <\/p>\n
Waterman discussed the necessity behind oil coolers in the southern states. \u201cOur newer pump purchases are all equipped with oil coolers, and we\u2019ve even retrofit some of our older models to incorporate them,\u201d says Waterman. \u201cBy increasing the viscosity and lowering the operating temperature, we\u2019ve increased the life of the hydraulic pumps.\u201d <\/p>\n
Regarding cleanliness, both contractors claim it\u2019s nearly a non-issue. \u201cI\u2019ve never found it necessary to explain the importance of having a clean concrete pump, says Murray. \u201c Thank goodness we\u2019ve got some neat freaks in here. We\u2019re always complemented on how clean our pumps are \u2013 that motivates my operators and my maintenance team to make sure we\u2019re representing the company appropriately.\u201d<\/p>\n
\u201cOnce again, it\u2019s in the hands of our operators,\u201d says Waterman. \u201cThey understand that Brundage-Bone has corporate standards and an industry-wide reputation. The majority of that, certainly in the general public\u2019s eye, can be attributed to the appearance of our pumps.\u201d<\/p>\n
Meyer Material\u2019s Lou Murray and Brundage-Bone\u2019s Randy Waterman commented on the benefits of stringent PM programs. <\/p>\n
\u201cBefore we implemented these standardized maintenance schedules we were essentially working by the honor system,\u201d says Murray. \u201cSome guys were more careful than others. We were having a lot of issues with our tires, and knew it would be beneficial for us to keep tabs on our maintenance. The manufacturers were blaming us for poor performance and we needed to document our practices. It simply expanded from there.\u201d<\/p>\n
\u201cIn terms of resale and trade-in value, I look at it the same way I do a used car,\u201d says Murray. \u201cIf you the buyer or manufacturer doesn\u2019t know what the pump\u2019s been through, there\u2019s no way they should accept it. I respect that and provide the appropriate documentation.\u201d<\/p>\n
\u201cWe have a vested interest in these pumps,\u201d says Waterman. \u201cNot only do some of these steps increase the life of the concrete pump, they increase the performance. We\u2019re able to service our customers with peace of mind and a lot of pride. The time it takes to implement a program is well worth it in the long run.\u201d <\/p>\n
In terms of resale, Brundage-Bone has one of the best track records in the industry. \u201cOur PM program has provided us a reputation, and there\u2019s never a problem selling one of our used pumps.\u201d <\/p>\n","protected":false},"excerpt":{"rendered":"
More than just a catch phrase, preventative maintenance supplies pump owners with several benefits including safety, reliability on the job site, higher resale value, and priceless peace of mind. Pumping contractors across the country are recognizing the importance of installing rigorous programs to protect their livelihood. Jeff Popa, Service Manager at Schwing America\u2019s White Bear, […]<\/p>\n","protected":false},"author":3,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"footnotes":""},"categories":[6],"tags":[],"class_list":["post-3966","post","type-post","status-publish","format-standard","hentry","category-news"],"acf":[],"_links":{"self":[{"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/posts\/3966"}],"collection":[{"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/comments?post=3966"}],"version-history":[{"count":0,"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/posts\/3966\/revisions"}],"wp:attachment":[{"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/media?parent=3966"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/categories?post=3966"},{"taxonomy":"post_tag","embeddable":true,"href":"http:\/\/schwinglatinoamerica.com\/wp-json\/wp\/v2\/tags?post=3966"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}