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CONCRETE TECHNOLOGY40 CPI %u2013 Concrete Plant International %u2013 4 | 2025 www.cpi-worldwide.comCompared to the profiles in Figure 1, which display characteristic pressure drops after each piston stroke, the profiles in Figure 2 exhibit pressure peaks after each stroke due to a fundamentally different hydraulic system configuration. Although both systems serve the same purpose, pumping concrete through pipelines, their operational signatures vary significantly. This underscores the necessity of adapting the analysis algorithms to different machine types, even when performing similar tasks. The wavelet transform visualizations further illustrate this point. During blockage-free operation, the frequency spectrum remains consistent and concentrated in expected bands. However, in cases of impending blockage, distinct anomalies emerge in low-frequency regions, where minimal activity is typically observed. These deviations can serve as early indicators of critical flow disturbances.OutlookThe pilot phase has demonstrated the feasibility and effectiveness of inline monitoring during concrete pumping using retrofit sensor modules and edge computing. Building on this foundation, further functionalities of the system are being explored.One of these is the detection of water additions during the transportation process in the mixing truck. By combining pressure signal analysis with machine-integrated data, the system can identify changes in material behavior that correlate with on-site modifications of the concrete mixture.The system is also designed to interface with the machine%u2019s internal data infrastructure via standardized protocols. This allows the edge device not only to process data from external sensors but also to access and integrate native machine parameters, enabling a more holistic view of the pumping operation.Moreover, the device is capable of generating output signals based on calculated blockage indicators. These signals can serve different functions: they can be used for data-based behavioral analysis and operator training, or in a more direct application, for real-time operator alerts. For that use case a vibration module can be integrated into the operator%u2019s remote control and signal incoming blockages. First test results show that the system can identify indicators of an imminent blockage up to 20 seconds in advance, offering a potential window to intervene and prevent a complete shutdown of operations.Looking ahead, a key objective is to extend monitoring across the entire concrete value chain. Rather than focusing solely on the point of placement, the aim is to trace relevant material and process parameters from production through transport to final installation. Such an approach could enable continuous optimization and enhanced process control.Finally, the EU Data Act provides both regulatory momentum and a framework for improving interoperability. In this context, there is a clear opportunity and need to develop cross-manufacturer standards for data exchange between construction machines. The long-term vision includes the creation of an open, interoperable platform that enables seamless communication and integration across equipment and systems from different producers.AcknowledgmentsThe authors thank BFU Betonf%u00f6rderunion GmbH & Co. KG and Perinet GmbH for their valuable collaboration during the pilot implementation of the Huckepack system. Their combined expertise in concrete placement and sensor integration was instrumental in realizing this project. nFig. 2: Pumping procedure without blockage (a) and with blockage (b). The colorful distribution represents the wavelet transform of the time-dependent signal. Figure 2b shows early indicators of the blockage, appearing 10%u201320 seconds before it occurs. a) b)Time, sWavelet TransformTime, sWavelet TransformTime, s Freq., Hz Freq., Hz Time, sHydraulic pressure, Bar Hydraulic pressure, Bar