{"id":87819,"date":"2020-01-28T19:02:00","date_gmt":"2020-01-29T00:01:59","guid":{"rendered":"https:\/\/zonda-develop.go-vip.net\/concrete-construction\/article\/making-concrete-pumpable_o"},"modified":"2020-01-28T19:02:00","modified_gmt":"2020-01-29T00:01:59","slug":"making-concrete-pumpable_o","status":"publish","type":"post","link":"https:\/\/zonda-develop.go-vip.net\/concrete-construction\/how-to\/materials\/making-concrete-pumpable_o\/","title":{"rendered":"Making Concrete Pumpable"},"content":{"rendered":"

As concrete mixes become more complex in order to address ever-increasing needs for strength and durability and to meet environmental sustainability standards, concrete pumpers often face challenges when it comes to moving concrete through pump lines with the efficiency demanded by accelerated construction schedules.<\/p>

\u201cWe pump at such high pressures today,\u201d says Gary Brown, director of concrete pumping for R.L. McCoy Inc., an Indianapolis, Ind.\u2013based concrete pumping company. \u201cIt places stress on the equipment.\u201d And that stress can cause equipment to fail.<\/p>

Brown says that since the 1990s, concrete producers have increasingly reduced water and cement (paste) content in favor of chemicals designed to increase performance. \u201cWhen you add chemicals, you take out cement,\u201d he says. \u201cI\u2019d like to see concrete pumping at a reasonable pressure again\u2014for safety. Chemicals aren\u2019t the only answer to making good concrete.\u201d<\/p>

BASF senior scientist and engineer Van Bui adds, \u201cThe first step is that the concrete mixture, including cement content and dosage of chemical admixtures, should be well proportioned and designed to achieve not only the required performance in the hardened state, but also satisfactory fresh properties such as workability, workability retention, pumpability, and placeability.\u201d<\/p>

How do construction teams make sure concrete mixtures meet the performance requirements of architects and engineers while also being efficient and safe to pump? Brown says the key is getting your pumping contractor involved early. \u201cWe know the materials, what we can tolerate, and what chemicals might be needed with a given mix,\u201d he says. \u201cIf I can\u2019t pump it, they can\u2019t sell it, and we want everyone to be successful.\u201d<\/p>\n

\n\t
\n\t\t\n\t\t\"\u201cA\n\t\t\t<\/div>\n\n\t\t\t
\n\t\t\t

Lloyd Concrete Services<\/p>

\u201cA good mix that pumps well will empty from the truck in 5 minutes,\u201d says Steve Lloyd. \u201cThat means quick turnaround and more money for everybody.\u201d<\/p>\t\t<\/figcaption>\n\t<\/figure>\n\n

Factors that Impact Pumpability<\/b>
A wide array of factors can impact concrete pumpability, Bui notes, such as the dimension, shape, gradation, and volume of aggregates. Supplementary materials like fly ash, silica fume, slag, and limestone also influence the rheology of the mix and therefore its pumpability.<\/p>

\u201cThe two main ingredients that make concrete pump are water and cement,\u201d Brown says, and while admixtures can increase pumpability, that will only happen if the supplier doesn\u2019t take out too much water and cement. \u201cIf you replace too much of that water and cement with a chemical, it may give the same slump, but it takes out pumpability. That doesn\u2019t mean the product won\u2019t pump, but the pumping will be slower, meaning a pumper may get 40 yards an hour instead of 90.\u201d<\/p>

Steve Lloyd, CEO of Lloyd Concrete Services Inc., in Rustburg, Va., agrees that water is critical to pumpability. \u201cA lot of people now want to do a chemical mix to replace the water,\u201d he says. \u201cThe concrete pump knows if the mix doesn\u2019t have enough water, and it won\u2019t pump without water.\u201d<\/p>

Tommy Rutura, president of New York\u2013based Ruttura & Sons, says a good water-cement ratio is critical. Ruttura, who pumped for the construction of the World Trade Center, says, \u201cIf you\u2019re pumping high-strength concrete with a water-cement ratio of 0.28, that\u2019s not efficient; we were only able to get about 20 yards an hour.\u201d It can also put a lot of pressure on the hose clamps. Ruttura says the ideal is to \u201chave at least 270 pounds of water per cubic yard, although we can pump it with down to about 230 pounds with a well-blended aggregate.\u201d<\/p>\n

\n\t
\n\t\t\n\t\t\"A\n\t\t\t<\/div>\n\n\t\t\t
\n\t\t\t

Putzmeister<\/p>

A wide array of factors can impact concrete pumpability such as the dimension, shape, gradation, and volume of aggregates and fibers.<\/p>\t\t<\/figcaption>\n\t<\/figure>\n\n

\u201cWhen we put out a proposal, we say the mix has to be pumpable,\u201d Lloyd says. \u201cAll mixes aren\u2019t the same. You have different types of aggregate in different parts of the country.\u201d The type of concrete also plays a role. Ruttura says normal-strength concrete between 3,000 psi and 6,000 psi pumps easily, but at higher strengths, the water-cement ratios become too low to pump at high volume.<\/p>

Very-high-strength vibrated and self-consolidating concretes with very low water-cementitious materials ratios can create high pressure in the pump due to high viscosity and high thixotropy (ability of the concrete to flow), according to Bui. But the opposite is also true\u2014self-consolidating concrete with poor mix designs, too-high slump flow, and insufficient cohesion can result in segregation and blocking, which also causes high pressure in the pump.<\/p>

\u201cOur industry fails to [remember that] the slump cone was designed in 1917, and was designed to test water added to a mix and maintain water consistency,\u201d Brown says. \u201cWe still use the slump cone as a measuring device but we may only be measuring chemical slump. The only thing that tells you how wet the concrete really is, is the water-cement ratio. The only true test is, will it go through the pump on the jobsite?\u201d<\/p>

Brown says that if pumpers keep an eye on the pressure gauge or operator box, they\u2019ll see that the pressure changes when the mix changes. \u201cIf the pressure is consistent start to finish, you\u2019ve got good-quality concrete.\u201d<\/p>\n

\n\t
\n\t\t\n\t\t\"\u201cThe\n\t\t\t<\/div>\n\n\t\t\t
\n\t\t\t

Lloyd Concrete Services<\/p>

\u201cThe concrete pump knows if the mix doesn\u2019t have enough water,\u201d says Steve Lloyd, \u201cand it won\u2019t pump without water.\u201d<\/p>\t\t<\/figcaption>\n\t<\/figure>\n\n

Pumping Fibers<\/b>
When it comes to fiber-reinforced concrete, synthetic and steel fibers typically don\u2019t decrease pumpability, but they can impact how fast one can pump. And, as Lloyd points out, macro-synthetic fiber can collect on the hopper grate. \u201cIt\u2019s important to modify your standard grate to a round and smooth grate,\u201d he says.<\/p>

Brown says his company recently completed a job where they had to pump concrete with 50 pounds of steel fiber per cubic yard, the highest dosage they\u2019d ever pumped. \u201cWe were able to pump it without issues; we just couldn\u2019t pump it as fast,\u201d he says, because the material tended to bridge in the hopper and so wouldn\u2019t load the cylinders completely full. Brown indicates the same can happen with synthetic fiber.<\/p>\n

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\n\t\t\n\t\t\"Concrete\n\t\t\t<\/div>\n\n\t\t\t
\n\t\t\t

R.L. McCoy<\/p>

Concrete pumpers often face challenges when it comes to moving concrete through pump lines with the efficiency demanded by accelerated construction schedules.<\/p>\t\t<\/figcaption>\n\t<\/figure>\n\n

Lightweight Concrete<\/b>
When it comes to lightweight concrete, Clint Chapman, west region marketing manager for Arcosa Lightweight in Boulder, Colo., says air entrainment can help with pumping, making the concrete more flowable and keeping the mix from segregating. He notes that water content is often higher in lightweight concrete than in standard-weight concrete and that sufficient aggregate moisture is critical in successfully pumping lightweight concrete. The critical factor is to make sure the lightweight aggregate is saturated surface-dry as it goes in so that it will not absorb water from the mix, especially under the pressure of pumping.<\/p>

\u201cYou can lose a lot of slump when you pump [lightweight concrete],\u201d Lloyd says. Because lightweight that is not saturated absorbs water so quickly, Lloyd advises putting the lightweight aggregate in a pit and soaking it before mixing. \u201cWater sprinkling is not enough,\u201d he cautions. \u201cYou will lose slump.\u201d<\/p>

Arcosa\u2019s Chapman disagrees that water sprinkling is not enough and notes that wetting aggregate with sprinklers \u201cis done with great success every day throughout the country. As long as the aggregate is pretreated with moisture sufficiently before pumping, slump loss will be minimized.\u201d<\/p>

Chapman also recommends a good-quality fly ash to help with pumpability of lightweight concrete. But with fly ash supplies sometimes tight due to the gradual elimination of coal-fired power plants, concrete producers will use slag in its place (which also helps contractors meet sustainability requirements by reducing cement). But R.L. McCoy\u2019s Brown points out that because slag is angular, it\u2019s far less pump-friendly than fly ash. \u201cThat means adding more chemicals to get back to pumpability,\u201d he says. Also, since concrete mixtures with slag pump more slowly, pumping contractors often have to use additional pumps to meet pumping volume requirements.<\/p>

Chapman says that with lightweight concrete, pump configuration is often the most likely issue to create pumpability problems. \u201cBoom angles can help or hurt,\u201d he notes. \u201cYou want as flat a boom angle as possible.\u201d As far as line diameter goes, Chapman recommends a minimum of 5 inches throughout the system with as much steel line as possible.<\/p>\n

\n\t
\n\t\t\n\t\t\"Rocky\n\t\t\t<\/div>\n\n\t\t\t
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Adobe Stock \/ sommersby<\/p>

Rocky mixes can collect on the hopper grate and bridge in the hopper or agitator area.<\/p>\t\t<\/figcaption>\n\t<\/figure>\n\n

Impacts of Aggregate<\/b>
Aggregate size can also impact pumpability, of course, though most pumps can handle up to 2-inch aggregate. As long as pumpers have a 5-inch system, says Brown, they shouldn\u2019t run into issues.<\/p>

ACI 304.2R, Guide to Placing Concrete by Pumping Methods, recommends the maximum size of angular coarse aggregate should be no more than one-third the smallest inside diameter of the pipeline. In the case of well-rounded aggregate, that diameter can go as high as two-fifths, since more-rounded aggregate goes through pump lines with fewer issues, as does natural gravel and natural sands because they\u2019re spherical in shape.<\/p>

Since mortar separates aggregate particles and rougher textures need more separation to achieve maximum pumpability and finishability, pumpers should pay attention to mortar volume fraction\u2014the percentage of concrete volume including everything except the coarse aggregate. That should stand at about 50% for most mixes using clean, rounded gravel. For crushed stone mixes, that figure should be closer to 60%. When mortar volume fractions get much higher than these numbers, it can lead to pump clogging.<\/p>

Pumping Aids<\/b>
<\/p>\n

\n\t
\n\t\t\n\t\t\"Well-designed\n\t\t\t<\/div>\n\n\t\t\t
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Schwing<\/p>

Well-designed mixes pump easily, are finishable, and meet all of the hardened specifications.<\/p>\t\t<\/figcaption>\n\t<\/figure>\n\n

Bui notes that some chemical admixtures aid pumpability by improving workability, reducing segregation, and increasing the lubricating effect between the concrete mixture and pipe surface. Without enough water in the mix, though, pumping speeds will slow; on the other hand, too much water or high-range water reducer (HRWR) can cause the mix to segregate. In mixes like that where there\u2019s the danger of coarse aggregate segregation, Brown says a viscosity-modifying admixture (VMA) stabilizes aggregates, especially with self-consolidating concrete.<\/p>

To indirectly improve the pumpability of high-strength concrete, Bui recommends using a medium-range water-reducing admixture and\/or a superplasticizer (HRWR), which increase workability and reduce the water-cementitious materials ratio. High workability, satisfactory workability retention, and enough cohesion in the mix improves pumpability, although close attention must be paid to good mix designs in which the paste is sufficient.<\/p>

Lloyd says he sometimes uses Slick-Pak, a polymer-based concrete pump primer, but after priming the pump, he doesn\u2019t use anything else because he doesn\u2019t want pump aids showing up in the slab where it can retard the concrete set.<\/p>

Get Ahead of the Job<\/b>
Pumping contractors unanimously agree that the key to ensuring that concrete mixes are pumpable (and pumpable at the required rates) is getting involved in the process early, but concrete pumpers aren\u2019t always included. Also, the more that architects and engineers look for cost savings and increased strength in their mixtures, the more likely pumpers are to face problems.<\/p>

\u201cProperly designed concrete is always going to pump,\u201d Brown says. \u201cGet ahead of the job. Talk to the ready-mix supplier and the contractor about the mix early on, so that once you\u2019re on the job you won\u2019t be standing there looking at each other when you\u2019re not getting the production you want out of the pump.\u201d Brown cautions contractors to work with their pumpers before they bid a job because if chemicals are needed and add to the per yard price, someone is going to have to pay for that.<\/p>

\u201cBefore we go to jobs, we have in-person meetings,\u201d Lloyd says. \u201cIf the concrete doesn\u2019t pump, it\u2019s going back to the plant.\u201d Lloyd says he cannot emphasize enough the dangers of a \u201cborderline mix.\u201d <\/p>

Bui recommends doing trials and mock-ups in advance of a pumping job to determine suitable pumping equipment, accessories, and procedures and emphasizes the need to \u201cenhance communication and collaboration among specifiers, contractors, concrete producers, and admixture suppliers within a project.\u201d<\/p>

\u201cA good mix that pumps well will empty from the truck in 5 minutes,\u201d says Lloyd. \u201cThat means quick turnaround and more money for everybody.\u201d<\/p>","protected":false},"excerpt":{"rendered":"

As concrete mixes become more complex in order to address ever-increasing needs for strength and durability and to meet environmental sustainability standards, concrete pumpers often face challenges when it comes to moving concrete through pump lines with the efficiency demanded by accelerated construction 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