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    Placing Concrete by Pumping Methods

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    ACI 304.2R-91

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    Placing Concrete by Pumping Methods

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    130 views17 pages

    Aci 304.2R-91

    Uploaded by

    venkateswara rao pothina
    Placing Concrete by Pumping Methods

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    © All Rights Reserved
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    1-91 Placing Concrete by Pumping Methods Reported by ACI Committee 304 Donald L. Houghion James H. Sprouse Howard E. Willey Secretary ‘Task Group It Committee 304 Joseph F. Arturo. Arthue P. Di Natalet Harry. MeLean James E. Bennett, 3, Richard J. Frazer J. Neal Mustard” eralé T: Burgeses Donald J. Halt ‘Orton W. Spanley Mfames L. Cope Roy Hawkins* Paul R. Stodola ‘Albert B, Crosby Wan E. Hout, Je.* Robert E. Tobin® Jess A Cutlip Bruce A. Lamberton Franc ©. Wilton Menibers of the committee voting on the 1991 changes: Paul R, Stodols Chairman Donald B, Graham Kurt R. Mebby James E. Bennet, Jr Neil R, Gup Richard W. Narva ‘Arthur ©. Chef ‘Terence C. Holland James 8. Pierce ‘Thomas R. Clapp James Hubbard Jokn H. Skinner HL James 1. Cope ‘Thomas A. Johnson William X. Sypher Wayne 5. Costa Robert A. Kelsey Henri Jean De Carbonel John C. King Robert M, Fahbach Williaa C. Reeth Janes %, Povey Cilfort Gosdnn Gary R. Mass Describes punps for wansportng and placing sructua conerete. Rigid Aft itine ave dscssed ond couplings ander accuse bed Recommendations for proponioning pumpable concrate met pt ‘imum predation of agyegsies; cline wae, comani, and admicun pepe iments and emphasize the need for field sig fal mis for papas, Inpenance of sanrating lightweight aggregates is sexed. Suggetont are Eben for layout of liner; for maintaining uniform delvey rae a wall oo uiform quali of concrete atthe end of he ine an for cleaning ou pip, lines This report doesnot cover shoeing or pumping of noesrucneel Insulating on ella Npes of concrete. Kerwords: admixtures aggregate gradation; aggregates; cement conical coare sucess, concrete contruction: conceles; conveyings couplings tne sawreanies, fineness modulus Ughivelght aggregate contrter lightweight sugresates; mix proportioning; plpelines: pipes (tubes) placing: ponzolan, ‘Pumped concrete: pumps, quality conto; wale content. 4ST Goninities Repos, Guiles, Siandard Praca and Commentaries ate intended for guidance in designing. planning, executing, or inspecting construction "and ia preparing ‘specifications, Reference to these documents shall not be made i the Project Documents. If items found in these documents ere desired to be part of the Project Documents they should be phrased in mandatory language and incorporated ino the Project CONTENTS Chapter 1 -- Introduction, p. 304.2R-2 Chapter 2 -- Pumping equipment, p. 304.2R-2 2.1 = Piston pumps Chapter 3 -- Pipelines and accessories, p. 304.2R-4 3.1 -- Rigid pipelines 3.2 -- Flexible conduit (hose) 3.3 -- Couplings 3.4 ~- Accessories 3.5 ~- Line resistance F Sewal Ga Task roup Hei prapered she report ‘steph teplacr ACI 3042870 (Rind 108) eff Near eliorut and moe rere hee been wade tt | w | 2 [a bw fw | oo ee tt — ge [ ete || z === = [oe | = le > [= [= ee ceamaios woe [Cae [em [| am _[ an a Sean ar La ate ts | sts ST Eames ab aE (| eet | [ne |» eee te Pe pep ® | D sere) eee eee tele wt ease | ste (ee |e eee eee gE asta Reg ee lhe Ie seep Uttase 14041 Its: I : ace inoue in factre. 4 Capachies were obtained by standard hydraulic formula (multiply erot-sctional area given in Colum 2 by velocities ted fa appropriate units. To obtain the rated capac for a particular conerete pump, consult the ‘Note: OD indicates pipe outside diameter. ID indicates pipe inside diameter. 04 Pipeline to provide 1 relatively constant flow of concrete through the pipeline into the placing area. The pistons and valve are hydraulically driven and primary power is provided by diesel, gasoline, or electric motors. Units are truck, trailer, or skid mounted and components are sized to provide the desired output volume and pressure on the concrete in the pipeline. Receiving hoppers vary in size from 4 f to 2y@ (0.1 to 1.5 m’) and are usually equipped with remixing blades 10 maintain consistency and uniformity CHAPTER 3 -- PIPELINES AND ACCESSORIES 3.1 - Rigid pipelines Most concrete transported to the placement areas by pumping methods is pumped through rigid steel pipe or a combination of rigid pipe and heavy-duty flexible hose. Rigid pipe, also termed “hard line" or “slick line” is available in sizes from 3 to 8 in. (76 to 203 mm) in diameter, wth 4 and 5 in, (100 and 125 mm) being the most ‘commonly used. Table 1 shows geometric and performance factors for common pipe sizes. Aluminum pipeline should \C not be used in concrete pumping? Rigid pipe is usually furnished in 10-ft (3-m) lengths. ‘The total weight of a coupling and a 10-ft (3-m) section of pipe filled with concrete increases rapidly with diameter. A 10-tt @-m) section of 5 in. (127 mm) pipe filled with ‘concrete will weigh about 273 Ib (124 kg) and is generally considered a practical maximum for one worker to handle, Larger size pipe or longer sections will require more workers, or power, for handling. The capacity of a pipe system depends on several factors: the concrete mix, length of line, height to which the concrete is being pumped, smoothness of the inside of the pipe, and the net inside clearance diameter. 32 Fenible condait (hose) Flexible conduit is made of reinforced rubber. ‘The performance of flexible conduit is not the sanne as that of Fight pipe; generally it presents greater resistance to the movernen! of concrete, The larger sizes, 410 $ in. (102 to 127 mm), have a tendency to kink more than the sialler izes, 2 10 3 in. (51 10 76 mm). Fleniole conduit is interchangeable with rigid pipe sections. This permits its use in curves, difficult placement areas, and as connections to ‘moving cranes or to water-borae Hines. In general, a 5-in. (125 mm) size is the largest flexible conduit that can be handled manually 3.3 ~ Couplings ‘The couplings used to connect both flexible and rigid pipe sections must be adequate in strength to withstand handling during erection of the pipe systom, misaligament, and poor support along the lines. They should be rated for the maximum pressure that can be exerted on the concrete by the pump being used. End or axial loads can be high on ‘the couplings in both rising and level runs. Accordingly, the coupling types vary with the size of pipe used; the larger sizes require considerably heavier fittings. Couplings should MANUAL OF CONCRETE PRACTICE ‘be designed to allow replacement of any pipe section without moving other pipe sections, and should provide a {ull internat cross section with no constrictions or crevices {0 disrupt the smooth flow of concrete. ‘The most popular couplers are the one piece extended lever swing type. These have pressure ratings of $00 psi 3.5 MPs) for grooved ends and 1000 psi (7 MPa) for raised tends. Two bolt couplers are rated at 800 psi (6 MPa) for ‘grooved ends and 3000 psi (21 MPa) for raised ends. 34 ~ Accessories Pipeline accessories are available as follows: 1. Rigid pipe and flexible conduit sections in varying lengths 2. Curved sections of rigid pipe 3. Swivel joints and rotary distributors 4. Pin and gate valves to prevent backflow in the Pipeline $. Switch valves to direct the flow into another pipetine 6 Connection devices to fill forms from the bottom up 7. "Splits" rollers, and other devices for protection of pipeline over rock, concrete, reinforcement steel, and forms, and to provide lifting and lashing points 8. Extra strong couplings for vertical runs, exposed or inaccessible areas, booms, and unsupported bends 9. Reducers for connecting different sizes of pipe 10. Ai vents for dowahill pumping 11, Cleanout equipment Several pump manufacturers offer power controlled booms or specialized cranes (Fig. 2). This equipment provides rapid, convenient power handling of the concrete Getivery pipe usually with a pendant concrete delivery hose, ‘These units are especially useful on column, wall, elevated slab, and scattered small placements, 35 ~ Line resistance When concrete is being pumped through a straight section of pipe or hose, it moves as a cylinder rid lubricant film of grout or mortar. direction or eross section some remixing occurs.’ Ia all cases a lubricating mortar is a necessity, and is obtained by. starting the pumping operation with a properly pro- portioned mortar or with a batch of the regular concrete with the coarse aggregate omitted. Once concrete flow through the pipeline is established, the lubrication will be maintained as long as pumping continues. The line coating mix should be wasted and not used in the concrete placement, When a change in direction occurs in the pipeline, increased resistance to movement takes place and greater wear results. Both line resistance and velocity {increase with a decrease in cross-sectional area, The shear {ace of moving concrete crossing stationary concrete in the idle leg of a "Siamese" or "Y" connection will increase line resistance and power requirement. To obtain the least line resistance, the layout of the pipeline system should contain a minimum number of bends with no change in pipe size. PLACING CONCRETE BY PUMPING METHODS: Fig. 2~-Concrete pump with placing boom supplying concrete for bridge deck Careful handling of the pipeline during assembly, cleaning, and dismantling will aid in lowering line resistence by preventing the formation of rough surfaces, dents in pipe sections, and crevices in couplings. CHAPTER 4 -- PROPORTIONING PUMPABLE CONCRETE toed. Basic considerations ‘Although the ingredieats of both pumped mixes and those placed by other methods are the same, more emphasis on quality controls essential to the proportioning and use of a dependable pump mix. Dependabiliry, as pre- viously mentioned, not only is affected by the equipment and the operators itis definitely associated with the control of all of the ingredients in the mixture, the batching and rising operations, and the knowledge and experience ofall the personnel from beginning to end. Concrete mixes for pumping must be plastic. Harsh izes do not pump wel. Particular attention must be given to the mortar (cement, sand, and water) and to the amouats and sizes of coarse aggregates. The principles of pfo-portioning are covered in several published documents. Particular reference in this report is made to ACI 211.1 and to ACI 211.2 covering the principles of proportioning for normal weight and for lightweight concrete. These basic principles are discussed in further detail as they pertain to ‘pumping mixcs, and data are given based on proportioas of nnixes that have been pumped satisfactorily. Pumps are sensitive to variations in gradations and in batch pro- portions. Once a mixture is proved to be pumpable, @ ‘consistent repetition of all {actors insures smooth operation. ‘The pumping process tends to remix, consolidate, and make the concrete more uniform. Pumping concrete frequently increases the cylinder compressive strengths and at the same time narrows the range of strength variation. 42 ~ Normal weight aggregates 42.1 Coarse normal weight aggregate ~~ The maxiaum size of angular coarse aggregate is limited to one-third of the smallest inside diameter of the pump or pipeline. For well rounded aggregates, the maximum size should be limited to 40 percent of the pipe or bose diameter. Provisions should be made for elimination of over-sized particle in the concrete by finish screening (ACI 304R) or by careful selection of aggregates. Gradation of sizes of coarse aggregate should mect ASTM C 33 requirements and be as close to the middle range as possible. It may be 306.26 necessary to combine and blend certain fractional sizes to produce proper gradation. Uniformity of gradation throughout the entire job from day to day is far more important than occasional perfect “down the middle” gradation, “The shape of the coarse aggregate, whether angular or rounded, has an ifluence oa the mix proportions, although both shapes can be pumped satisfactory. The angular pieces have a larger surface atea per unit volume as compared to rounded pieces and thus require relatively more mortar to coat the surface “The maximum size of the coarse aggregate has a significant effect on the volume or amount of coarse aggregate that may be efficiently used. As can be seen in Table 2 the quantity of coarse aggregate must be substantially reduced a8 the maximum size is reduced. 42.2 Fine normal weight aggregates -- The properties of the fine aggregates or sand play a much more prominent role inthe proportioning of pumpable mixes than do those of the coarse aggregates. Together with the cement and water, the fine aggregates provide the mortar or fluid which ‘conveys the solids or coarse aggregates in suspension thus rendering a mix pumpable. ‘The gradation of the fine aggregate, which constitutes Allof the particles passing the No. 4 screen (3/16 in. or 4.75. mm), should conform to the requirements of ASTM C33, for sand. Experience has shown that particular attention [ Table 2 -- Volume of coarse aggregate per unit volume of concrete * (MANUAL OF CONCRETE PRACTICE should be given to those portions passing the finer screen sizes." For small line systems (less than 5 in. ot 125 mm) 15 to 30 percent should pass the No. 50 screen (300 um) and 5 to 10 percent should pass the No. 100 screen (150 jum). Sands which are deficient in either of these two sizes should be blended with selected finer sands to produce these desired percentages. However, use of greater than the above amount of these finer fractions requires the use of additional water which may cause excessive shrinkage and be harmful to strength. ‘An indication of the relative fineness of the sand may be determined from the fineness modulus. The fineness modulus of sand meeting ASTM C 33 gradation spe- cifications will fal! between 2.30 and 3.10 with the median being 2.70. Higher values of fineness modulus indicate coarser materials, Pumpability of mixes is generally improved with a decrease in the fineness modulus, or in other words, with the use of finer sands. Sands having a fineness modulus between 2.40 and 3.00 are generally satisfactory provided that the percentages passing the No. 50 and 100 sieves (300 and 150 zm) meet the previously stated requirements. The fineness modulus alone, without - stipulations about particle distribution, may not produce satisfactory results. With the finer sands (lower values of fineness modulus), larger quantities of coarse aggregates may be used, as shown in Table 2. It should also be ‘emphasized that for uniformity, the fineness modulus of the T Volume of dry-todded coarse aggregatet Maximum size per unit volume of concrete for different of aggregate fineness moduli of sand iv sam (approx) 240 2.60 280 | 300 % 10 0.50 048 046 os % 3 039 057 oss 033 % 9 0.66 0.64 0.62 0.0 1 2s om 0.69 0.67 06s % 38 o7s on on 0.69 2 a 078 ee on * Excerpt from table in ACI 211.1 they may be increased about 10 percent. For more workable concrete, such as may sometimes be required when placement is to be by pumping, they may be reduced up to 10 percent. + Volumes are based on aggregate in dry-rodided condition as described in ASTM C 28. “These volumes are selected from empirical relationships to produce concrete with a degree of workability suitable {for usual reinforced construction. For less workable concrete, such as required for concrete pavement construction, PLACING CONCRETE BY PUMPING METHODS sand should not vary more than 0.20 from the average value used in proportioning, This tolerance is commonly applied in conventional concreting specifications. Concrete sands may be obtained from natural deposits, ‘or may be manufactured by crushing and grinding coarser materials to the desired sizes. The pumping characteristics of these sands may vary, but it appears that the fineness modulus is a good indicator of the acceptability of either type. More ot less of any particular particle size than ASTM C33 permits for sand should also be avoided. Small quantities of materials such as crusher dust, wash pit setlings, ly ash, and beach or dune sand are often useful in correcting deficiencies in the finer sizes. Experience indicates that combining materials from separate sources often brings excellent results. The use of as little as S Percent of river sand may render crushed rock sand Pumpable. In the same way, small additions of rock fines may improve the pumpabilty of natural sands, particularly where dredging has washed out the finer sizes, Additions of as little as 25 Ibid? (15 kg/m?) can create a noticeable {rovement in pumpabilty of a mixture. Table 2 is suggested as a guide to determine the amounts of coarse aggregate to be combined with sand of different fineness modulus values. Particular attention is irected to the footnote for Table 2 which permits a reduction in the volume of coarse aggregate of up to 10 percent for pumping, This reduction provides a safely nargin for variations in sand gradation and reduces Pumping pressures. Under conditions of good materials control and uncomplicated line systems, this reduction may not be required. As a guide in sclecting suitable sand, the solid-tine ‘curves in Fig. 3 and 4 are suggested, In Fig. 3 the percentage passing each sercen size is shown together with ASTM fimits, while in Fig, 4 the individual percent retained fon cach screen is shown, Both solid curves represent ideutical data, Although in practice it may be impossible to uplicate this recommended sand gradution exactly, sands having a grasation closer to the upper lint (fine sand) are nore desirable for pumping than those neur the kewer lint (ovrse sand). ‘The fineness modulus of this composit Tm sial is 2.68; the gradation mecis ASTM C 33 specifications and produces a smooth curve, and the percentages passing the No. 50 and No. 100 screens (300 and 150 um) are well withia the limits prescribed previously. 423 Combined normal weight aggregates -- Fig, 5 contains combined aggregate gradation bands for 3/4 in (19 mm) and 1 ia, 25 mm) maximum sizes which from experience have provided concrete with superior pumping characteristics. Although not shown, the curves can be readily extended for 1 1/2 and 2 in. (38 and 51 mm) ‘maximum aggregate sizes. The suggested values shown in Table 2 may be used for either angular or rounded coarse aggregates. The amount of mortar required to maintain the same degree of Pumpabiliy, because of differences in particle shape and ‘rading is compensated for automatically by differences in souzn7 éry-rodded void content, Values beyond the range of the table, especially higher fineness modulus values, should be ‘voided based on current experience for pump mites. 43 ~ Lightweight aggregates 43.1 Introduction ~~ Lightweight aggregate structural concrete has many economic applications and advantages in building construction. This material is particularly sulted to mutistory construction, and the use of pumps for placing it hhas become desirable and feasible in many instances. 43.2 Increasing moisture content of lightweight aggregate - « Lightweight aggregates usually have porosity character. istics which may cause them to absorb amounts of water. Allowances are made for this absorption ia ACI 211.2. Absorption under atmospheric pressure may vary for rent porous aggregates from 5 to 25 percent by weight. Under the pressures exerted by pumping, absorption may be considerably greater. If absorption is_ significantly increased during pumping, water loss from the mortar impairs its fluid properties and the pumpability of the conerete, Therefore, to pump lightweight concrete necessary 10 pretreat these aggregates enough to prevent ‘excessive stiffening during the pumping operation. ‘The degree to which the aggregate must be saturated depends somewhat on the horizontal and vertical distance the lightweight concrete is to be pumped. However, less than super-saturated aggregate usually results in erratic performance, except for short distances. Handling and ‘mixing of unsaturated lightweight aggregate tends to expose areas of the aggregate which will absorb more water. A more detailed discussion of methods of saturating lightweight aggregates is given in ACI 3045R. 43.2.1 Coarse aggregate - The total amount of water absorbed by lightweight aggregate soaked or sprinkled at atmospheric pressure increases with time but the rate of absorption of some lightweight aggregates is very rapid at fiest and later tapers off. Lightweight coarse aggregate for pumping may be presoaked in stockpiles or bunkers prior to use in concrete. Experience has shown that from 2 19 2 days of sprinkling is required, but the actual time required should be based on appropriate test or experience on the articular aggregate being used. This presoaking may be ‘accomplished by suitable sprinkling for penetration to the full depth of the material. Sprinkling should be temporarily discontinued when free water appears at the base of the material. Sprinkling should be resumed and repeated several times to provide additional water for additional absorption over 2 to 3 days. The moisture content of this presoaked material should preferably equal or exceed the average 24-hr absorption as measured by standard ASTM. tests (se¢ ASTM C 127). To permit uniform slump control, free water should be allowed to drain away before using the aggregate in concrete. It is generally necessary to modify the mixture to compensate for the additional absorption (or slump loss) which occurs during pumping, The slump of the concrete going into the pump must be increased and the coarse ‘aggregate content must be reduced, sometimes by as much 304.2R-8 100 90 MANUAL OF CONCRETE PRACTICE Ne |—Fine sand 80 . Recommended gradation 5 — 70 === ASTM C 33 limits 60 50 Coarse san 40 Percent passing by weight 30 20 10 s o+ mm. 635 Number (/4-in. + — 476 238 4 8 Lig 0595 «297 16 30 50 Screen size Fig. 3-Recommended normal weight fine aggregate gradation (percent passing) ~ = [t- 0.149 0.074 100 200 Be 20 BS ~ ie 3 ev s= ss" 1 85 & ° | mm 6.35 476 2.38 9 0,595, 0.297 0.149 0.074 Number (/4-in, 4 4 8 6 w» 50 100 200 Screen size Fig. 4-Recommended normal weight fine aggregate gradation (individual percent retained) PLACING CONCRETE BY PUMPING METHODS. s082R0 PARTICLE DIAMETER (Sieve No. and Inches) #200 #100 SO #30 #1 CAREY 90 ff Tin. (25.4 mm) sol | Max Aggregate Bond _— HB z Hein. V9.1 mm) © | |mox. Aggregate Bon 1 2 ze 2 3 & so ne Z = 40 | é Et To = 20 10 I oLt 0.01 o1 10 10 100 PARTICLE DIAMETER, MM. Fig. S:-Recommended combined aggregate gradation for nonmal weight aggregates as one-third of the quantity normally used in lightweight concrete. (Table 4 indicates the quantity of presoaked ‘cc aggregate which is generally used.) More sand may b&.dquired and sometimes itis also necessary to use finer sands, air-entraining agents, water-reducing admixtures, and/or pozzolans to further improve pumpabily 43.2.2 Fine aggregates — Presoaking of lightweight fine aggregates should receive as much attention as the coarse lightweight materials. If these fine materials are soaked in a stockpile or bunker, itis more difficult for the ‘water to penetrate through the mass or the total depth of the material. However, each individual grain or particle, when it comes in contact with water, will attain its absorption per unit of volume at a much faster rate than coarse pieces. Presoaking helps to prevent segregation of sizes but oversoaking may wash out the extremely fine particles which are critically needed. Presoaking of lightweight fines is occasionally accomplished in the mixer «drum with about two-thirds of the total mixing water before adding other ingredients. Presoaking by this method is accomplished in approximately S min. Presoaked fine lightweight aggregate will probably introduce some surface nipisture along with the absorbed water to the mixture. Proper allowances for this surface water must be made to contro! the slump of the concrete. However, the total water, that is, the surface water and the absorbed water, should be determined prior to batching by weight to insure that the proper absolute volume of sand is introduced into the concrete (see ASTM C 128). 43:23 Vacuum saturation -- A process for saturating ligheweight aggregates has been developed wherein the ag- sgregates are placed in a tank and saturated under a vacuum.” The moisture absorption by this process, which is ‘complete in 30 to 45 min, may be two to three times the regular 24-br absorption. When vacuum saturated light- ‘weight aggregate is used in concrete, it responds 10 pumping much the same as normal weight aggregates. Because of the relatively high degree of saturation, the aggregate particle resists further absorption. Therefore, the same proportioning procedures recommended for normal 306.2R-10 ‘weight concrete pump mixes should be used. (Coarse aggregate proportions shown in Table 2 may be used with ‘an appropriate allowance for the difference between dry loose and dry rodded volumes. Increase dry rodded volumes approximately 10 percent to convert to dry loose volumes.) 43.24 Thermal saturation Another process for saturating lightweight aggregates which has been suc- cessfully used at some lightweight production plants, consists of immersing heated aggregate in water. To avoid thermal shock and possible damage to the aggregate, the optimum combination of aggregate and water temperatures, can be determined in advance for any specific aggregate. This process is particularly adaptable to plants with ‘mechanical cooling equipment such as rotary coolers Moisture absorption by this process may be equivalent 10 vacuum pi 43.2.5 Retention of moisture ~ Lightweight aggregates treated with the vacuum or thermal saturation process may be stockpiled for over 90 days without significant loss of moisture. Concrete made from saturated lightweight ag- _Eregate should be allowed to cure for several weeks before itis subjected to freezing and thawing cycles. 433 Coarse lightweight aggregates -- The gradation of the coarse lightweight aggregates should fall within the limits stated in ASTM C 330. Most lightweight producers will have either 1/2 or 3/4 in, (12.5 or 19.0 mm) maximum sizes, or both, available. The aggregate producer should be consulted for suggestions and recommendations on this and all aspects of proportioning. Iti important to mention that the lightweight aggregates may fluctuate in their basic unit weight. Such variations within limits are recognized and permitted by ASTM C 330. These changes in unit weight may be due to the expanding characteristics of the raw ‘material, changes in moisture content, changes in gradation, fora combination ofall three. Adjustments in batch weights to compensate for these changes is imperative to maintain consistent absolute volumes of aggregate and proper yield Batching of lightweight c ites by volume rather than by weight is another well established method used for maintaining. consistency aud volumetric yield (see ACI 304.5R). ‘Structural lightweight aggregates may have a coated or uncoated exterior surface depending on the production method. They also may be either rounded, cubical, or ‘angular shaped pieces. In any case proper allowances may bbe made for shape and surface texture to handle any type of lightweight aggregate in a pump mixture. These allowances are made by slight changes in the ratio of ‘mortar to coarse aggregate. In some localities, coarse lightweight aggregates larger than the No. 4 screen (3/16 in, or 4.75 mm) are produced in two separate fractions. These two sizes should be combined (preferably at the batch plant) to produce a blended total coarse aggregate combination which satisfies current ASTM C 330 gradation specifications. Uniformity of gradation should be carefully maintained from one batch to the next, since fluctuations will affect the degree of pumpabilty. MANUAL OF CONCRETE PRACTICE 434 Fine lightweight aggregates -- The gradation of fine lightweight aggregates should also fall within the limits shown in ASTM C 330. Ia addition, it is imperative to pay specific attention to the very fine fractions. From 20 to 35 percent should pass the No. $0 screen (300 m) and 10 t0 20 percent should pass the No. 100 screen (150 um). Ifthe lightweight fines are deficient in these sizes, some aggregate supplement or mineral admixture, such as pozzolan or rock dust in approximately the amount of the deficiency, will improve pumpability. In some instances it may be possible to blend lightweight fine aggregate with natural sands. This practice may entail some dual considerations. Replacing lightweight fines with natural sands may improve the overall gradation ‘ofthese combined fine aggregates but it may also adversely increase the weight of the finished concrete mixture. Adverse weight effects, however, might be of relatively small amounts of very this combination results in improved gradation. Although the pumpability of a mixture may definitely be enhanced by the addition of minus 50 (300 um) to minus 200 (75 wm) ‘mesh fractions in the sand, it should also be remembered that too great an increase in these very fine sizes will require greater amounts of mixing water which reduces the strength and increases the drying shrinkage. ‘The fineness modulus ofthe lightweight fine aggregate requires some further comments in addition to those previously stated on the fineness modulus for natural sand, ‘These comments are taken from ACI 2112. For normal weight aggregates the bulk specific gravities of fractions retained on the different sieve sizes are nearly equal. Percentages retained on each size indicated by ‘weight, therefore, give a true indication also of percentages by volume. However, the bulk specific gravity of the various size fractions of lightweight aggregate increases as the particle size decreases. Some coarse aggregate particles may float on water, whereas material passing the No. 100 sieve (150 jm) may have a specific gravity approaching that of natural sid. IC is the volume occupied by each size fraction, and not the weight of material retained on each sieve, that determines the void content and required paste content, and influences workability of the concrete. Percentages retained on each sieve, and fineness modulys by weight and by volume, are computed for comparison in the example of Table 3. ‘The fineness modulus of 3.23 by volume in the example indicates a considerably coarser grading than that normally associated with the fineness modulus of 3.03 by weight. ‘Therefore, the lightweight aggregates tend to require @ larger percentage of material retained on the finer sieve sizes, on a weight basis, than do normal weight aggregates, to provide an equal size distribution by volume. Since itis impractical to calculate the fineness modulus of lightweight fines on # volume basis, it is suggested that it be figured on a weight basis similar to normal weight sand, If an arbitrary allowance of 0.20 difference in fineness modulus is made between natural and lightweight fines, the suggested range of fineness modulus for lightweight PLACING CONCRETE BY PUMPING METHODS. 042k ‘Table 3 - Comparison of fineness modulus by weight and by volume for a typlcal lightweight aggregate Cumulative Bulk ‘Cumulative Percent percent specific | Percent | percent Sieve Opening retained retained aravity | retained | retained see | in mn by weight | by weight | sd. basis | by volume | by volume No. 4 | 0.1870 475 o 0 ~ ° 0 8 | 00937 236 2 a 155 6 26 16 | 00469 118 mw 6 1.78 25 st 30 | 00234 | 0.600 w 65 1.90 ” ” so | oon7 | 0300 “ 9 201 3B B 100 | 0.0059 | 0.150 2 3 2.16 10 2 ntl ° fa [gat |tetg tet * Basod on table in ACI 211.2. Fineness modulus (by weight) = 3.03 becomes 2.20 to 2.80 as compared to the previously stated values of 2.40 to 3,00 for natural sand. Experience to date does not indicate the need for any greater accuracy, If natural sand is blended with the lightweight fines, the combined fineness modulus calculated on a weight basis should also fall within the limits of 2.20 to 2.80, 435 Combined lightweight aggregates ~The proportioning of coarse and fine aggregates to produce ‘pumpable lightweight concrete is probably an ert as well as ‘a science and reliance should be placed on the experience Of the aggregate producer. In many areas, only a limited selection of materials may he available and it may be necessary to import other supplemental products to achieve the best resulis. For example, a pozzolamie material might ‘be successful used as a fine aggregate supplement, and in other cases lightweight mixes arc designed with 100 percent ‘normal weight sand. Pozzolanic materials in the small amounts generally used for gradation benefication have no significant effect on the unit weight of the concrete, Table 4 is suggested as a guide for the amount of coarse lightweight aggregate that might be selected for trial mixes in lightweight concrete when atmospherically soaked ‘aggregate is used. In contrast to Table 2, the tabular values are given in terms of loose volumes to conform with ASTM specifications (see ASTM C 330). The values for fineness modulus shown in Table 4 are intended for the combination of all fine aggregates including natural sands or mineral supplements if they are used. Differences in particle shape, gradation, surface characteristics, void contents, and degree of presoaking may each have an influence on the optimum volume of coarse aggregates for particular mortar. It is emphasized that these values are suggestions based on ‘experience only and might easly vary as much as 10 percent Fineness modulus (by volume) = 3.23 above or below those shown for particular local conditions as well as for specific pumps. 44 ~ Water and slump Water requirements and slump control for pumpable normal weight concrete mixes are interrelated and ‘extremely important considerations. The amount of water used in a mix will influence the strength and durability (for a given amount of cement) and will also affect the slump or wworkabili ‘The mixing water requirements vary for different maximum sizes of aggregate as well as for different slumps. ‘A table showing the approximate quantity of water for different conditions is given in ACI 211.1 for both now-air- entrained and air-entrained concrete. It should be ‘emphasized that these values are only approximate and may require some changes due to the amount or fineness of the sands or quantity of admixtures, additives, cement replacements, or other special materials being used in the concrete. For lightweight concrete, the total water requirements will be different than for normal weight mixes. This is due to differences in the absorptive properties of the aggregates. Ifthe total water in a lightweight mix is divided into two segments, that is, into “active” water and "absorbed" water, it simplifies the considerations. The "active" water will establish the slump and have a direct bearing om the water-cement relationship. The absorbed water, however, will be contained within the lightweight particles and will rot change their displaced volume in the mix. Also, the absorbed water as such, will not directly affect the quality fof the paste, The requirements for active’ water in lightweight concrete are approximately the same as for a 206.2R-12 MANUAL OF CONCRETE PRACTICE Table 4 ~ Suggested volume of stmospherically soaked coarse lightweight oggregate per cubic yard (cubic meter) of concrete® Inch-pound units Fineness modulus of combined fine aggregatest Maximum size lightweight 220 240 2.60 2.80 aggregate, in. Coarse aggregate, {thd % 97. 93, as 85 % 1s ua 107, 103, % Bs B2 28 124 ST metric units Fineness modulus of combined fine aggregatest Maximum size lightweight 2.20 2.40 2.60 2.80 Vv aggregate, mm Conrse aggregate, ma? 94 0.34 0.33 031 125 oat 039 038 18.8 0.49 0.47 0.46 * Volumes are based on lightweight aggregates in loose condition as described in ASTM C29. Values ate based on an unpublished survey of average practices by United States lightweight aggregate producers. Experience has shown that the minimum time required for atmoshperic soaking may be 2 to 3 days. Actual time required should be based on appropriate test or experience on the particular aggregate being used. + Fineness modulus by weight; sec comments in Section 43.4 similar mix inv regular concrete. The absorbed water, as mentioned previously, will vary and to minimize thesevariations, saturating the lightweight aggregate has \bcen emphasized. Additional absorption due to pump pressures will be discussed under slump control To establish the optimum slump for a pump mix and to maintain control of that particular slump through the course of a job are both extremely important factors. Experience indicates that slumps below 2 in, (51 mm) are impractical for pumping and slumps above 6 in. (152 mm) should be avoided. In mixtures with high skimp, the ‘aggregate will segregate from the mortar and paste and may ‘cause blocking in the pump lines. Overly wet mixes also ‘exhibit excessive bleeding and increased shrinkage. It is ‘much more important to obtain a truly *plastic* mix through proper proportioning than to try to overcome deficiencies by adding more water. Most pump operators realize that ‘excess water added to the hopper of the pump creates more problems than it solves. “There are several reasons why the slump of concrete may change between init Some of these are variations in the setting time of cement dduo 10 physical or chemical propertics; variations in ambient air temperature or concrete mix temperature during mixing and pumping; variations in the temperature of cement, water, and aggregates; variations in the behavior of admixtures such as accelerators and air-entraining agents; ‘and variations in the water requirements and absorptive capacities ofboth normal weight and lightweight aggregates. If additional absorption in lightweight concrete does coceur during truck mixing time, the mix should be brought to the specified slump by the addition of extra water to offset that which was absorbed. This practice will not detract from the basic strength since the original proportions were predicated on sufficient "active" water to produce the desired strength at that slump. Ifa stump loss takes place in lightweight mixes between the pump and the discharge hose this may be due to further aggregate absorption under pressure. It may be due to insufficient saturation of the lightweight aggregates, too much coarse PLACING CONCRETE BY PUMPING METHODS. aggregate for a pumpable mix, abnormally high pumping pressures, or a combination of these plus other less obvious causes. If the slump at the discharge hose can be maintained within specification limitations, it may be satisfactory for the concrete to enter the pump at higher slump, if, as previously stated, the change is due simply to aggregate absorption. 45 ~ Cement content ‘The determination of the cement content for a normal ‘weight pump mix follows the same basic principles used for any concrete. The specific water-cement ratio may be ‘established on the basis of exposure conditions, strength requirements, or minimum cement factor, whichever governs. This is explained in complete detail in ACI 211.1. Because of the slightly higher ranges in slump and the previoualy discussed ratios of fines to coarse aggregates, pump mires may require an increase in the amount of cement used, ‘The cement contents for pumpable lightweight tes follow the general principles discussed in ACI 2 for lightweight concrete. It is recommended that the lightweight aggregate producer be consulted on cement ‘content requirements for his particular material to meet the necessary strengths. It should be recognized that pumpable lightweight mires which use higher ratios of fine to coarse aggregates or higher slump input may require an upward adjustment in cement contents. In establishing the cement content for normal weight or lightweight trial mixes, it is well to remember the need for ‘overstrength proportioning in the laboratory to provide for field variations which produce lowered strengths. A ‘complete discussion of the subject of evaluation of concrete ‘compressive strength may be found in ACI 214. ‘The use of extra quantities of cement as the only solution 10 the correction of pumping difficulties is both shortsighted and uneconomical. It is far more desirable as ‘well as economical to first correct any deficiencies in the aggregates, especially in the sand. With well graded coarse and fine aggregates properly combined, the cement factors * pump mixes will closely paraliel those used in other datrete, 46 ~ Admictures ‘Aay admixture that increases workability in both normal weight and lightweight concretes will usually improve Pumpability. The choice of type of admixture and the advantages gained from its use in concrete to be pumped will depend on the characteristics of the pump mix. When an admixture is selected for use as an aid in concrete pumping, it may provide additional lubrication, reduce segregation, and decrease bleeding, ‘Admistures used to improve pumpabilty are generally classified as: 1, Water-reducing admixtures 2. Aireotraining admixtures 3. Finely divided mineral admixtures 4, High-range, water-reducing admixtures s082n43 Itis beyond the scope of this report to discuss all types of concrete admixtures. Refer 10 ACI 2123R for a general discussion of all types being used. ‘The primary benefit to be derived from water-reducing admixtures is a reduction in water requirement at constaat slump or an increase in slump at constant water-cement ratio, Some may be designed to bave no apparent effect on setting time, others to achieve varying degrees of acceleration or retardation in rate of hardening of the mixture, and some of these materials may contain air- centraining agents. Most water-reducing admixtures enhance the air-eatraining properties of both air-entraining cement and pure air-entraining admixtures, and increase the Pumpability of the concrete mix. Frequently the gain in compressive strength at all ages is greater than the water reduction might indicate. High-range, water-reducing admixtures (Superplasticzers) are very effective in increasing the pumpability of concrete. However, they may be effective for only a limited time. Concrete which depends on superplasticizers for pumpability must be

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