Professional Documents
Culture Documents
74-19
This paper describes test methods developed for tion was available concerning the proportioning
examining the pumping characteristics of concrete and testing of concrete mixes for pumping.
which have aided the range of studies undertaken Over the last 8 years a number of investigations
on pumped concrete over the last 8 years.
Details are given of the basic state of the con- were carried out into the basic mechanisms of
crete in the pipeline, from which is established the concrete pumping both theoretically and by ob-
importance of impermeability of the material in servation in the laboratory and on site pipelines.3.4
minimizing pipe blockage. A practical test method It was during these investigations that test meth-
for this property, simulating the pressurized state
of concrete in a pipeline, is described, together with
ods for pumpability were considered.
test results from pumping trials on a number of This paper briefly summarizes the understand-
concrete mixes. ing developed of the basic state of concrete in a
Viscometric methods are also briefly mentioned pipeline and the mechanics of concrete pumping
in relation to the laboratory measurement of flow
in relation to the following three test methods
resistance.
The void meter test is described and its value for measuring the pumpability of fresh concrete:
as a mix proportioning tool is considered in rela- 1. The pressure bleed test to measure the in-
tion to the optimization of cement contents. ternal resistance of concrete to "dewatering;" this
Finally, the details and results from instrumen- was found to be a major cause of blockages.
tation of pipelines to observe pumping pressure
variations are presented and conclusions are given 2. The voids measurement of the total aggre-
related to pump performance and concrete charac- gates as an aid to mix proportioning of pumpable
teristics. concretes.
Keywords: concretes; field tests; fresh concretes; mix pro-
portioning; permeability; pumped concrete; pumping; pumps;
test equipment; tests; voids; water; water-cement ratio; work- ACI member Roger D. Browne, is a char-
ability. tered civil engineer and head of the Re-
search Laboratories of Taylor Woodrow
Construction Ltd., Southall, England. He
• IN RECENT YEARS CONCRETE PUMPING systems received his PhD in the field of high altitude
aerial photography and his diploma in
have been increasingly used in an attempt to in- photogrammetry at University College, Lon-
crease the speed of construction. This has been don, in 1959. Since that time, he has in-
vestigated many aspects of concrete tech-
particularly influenced by the development of nology in relation to the development of concrete pressure
mobile and truck mounted pumps fitted with tele- vessels for nuclear power stations and offshore structures,
as well as more conventional constructions.
scopic booms, which provide a completely inde- Dr. Browne has coauthored publications on the long term
pendent and flexible means of concrete placement. properties of concrete at normal and elevated temperatures,
resin concretes, high pressure water jet cutting of concrete,
Although concrete has been pumped success- large concrete placements, admixtures, strength in situ, and
fully for many years, variations in aggregates, marine durability of concrete.
hatching, and mixing can still make it difficult to Phillip B. Bamforth is at present a research
guarantee completely trouble-free concrete on engineer with Taylor Woodrow Construction
Ltd., Southall. England. He received his BSc
every occasion. The blocking of concrete in a pipe, in civil engineering from Leeds University in
therefore, may still present problems due to the 1970 and since that time has been involved
in the investigation of various aspects of
disturbance that such a condition can cause to concrete technology including pumping,
smooth and efficient site operation. early age behavior of mass placements, and
creep in relation to prestressed concrete
At the start of the present investigation in 1967, pressure vessels. He has coauthored publications on the
it was found that although various workers, such performance of concrete pressure vessels and effect of
cement replacement materials on the early age behavior of
as Ede 1 and Weber,~ had examined the behavior of Ia rge placements.
concrete in the pipeline, little practical informa-
FLOW RESISTANCE
Degree of saturation
The resistance to the flow of concrete in a pipe-
line is thought to be a combination of hydraulic
shearing of the lubricating layer and friction of the
solid particles in contact with the pipe wall. The
extent to which frictional resistance is effective,
however, depends greatly on the state of satura-
tion of the concrete.
LUBRICATING LAVER When concrete is in a saturated state (i.e., when
there is sufficient water in the mix to overfill the
voids of the dry materials) the magnitude of fric-
tional resistance is negligible compared with that
VELOCITY found when the concrete is in an unsaturated state.
PROFILE This effect was clearly shown by Ede 1 who
measured the flow resistance of a single concrete
with a varying water-cement ratio; the results are
PLUG
presented in Fig. 2. It will be seen that, as the
water-cement ratio and hence the workability was
Fig. 1-Piug flow reduced, the flow resistance increased and there
was a critical level of water-cement ratio, in this
3. The measurement of concrete pressure in a case 0.45, below which the frictional resistance in-
pipeline to give information on the efficiency of creased dramatically.
the pump and also the performance and pumping The sudden increase in flow resistance may be
characteristics of the concrete. attributed to the change from the saturated to
Much of the material in this paper is based on the unsaturated condition.
an investigation carried out for the Construction The pressure distribution down a pipeline for
Industry Research and Information Association, the saturated and unsaturated states may be ex-
and it is given here with CIRIA's permission. pressed as follows:
STATE OF CONCRETE IN THE PIPELINE
Saturated (hydraulic) flow 1•2-Under saturated
conditions the pressure loss in the pipeline has
Development been observed to be linear,l· 2 and the pressure at
Although direct observation of the internal be- any point in the line can be defined by the simple
havior of concrete while flowing under pressure expression:
through a pipeline has proved impossible, the
theoretical and experimental studies undertaken p =p 0 _ 4Rx
D (1)
on the pressurized state of fresh concrete and
measurements made of pressures at the pump and where
the pipe wall, together with observations of the P pressure in the pipeline at a distance x
state of the concrete at the end of the line, have from the pump (under saturated con-
provided the following understanding of the state ditions, axial = radial pressure)
of concrete in a pipeline. Pn pressure at the pump end of the line
(i.e., when x = 0)
Plug flow D internal pipe diameter
Concrete flows in a pipeline in the form of a R = flow resistance/unit area of pipe
plug separated from the pipe by a lubricating
layer of water, cement, and fine sand particles. The derivation of Eq. (1) is included in Appendix
The plug consists of aggregate, sand, and cement A.
particles separated by a continuous water layer The flow resistance has been shown to be made
which is hydraulically linked to the lubricating up of two separate components, the adhesion re-
layer. The velocity is constant across the width of sistance A, which exists even when the concrete is
the plug, i.e., there is no relative velocity between stationary, and a factor related to the velocity V
the aggregate particles, and drops rapidly across of flow in the pipeline and is given by the equation
R _ (P1- P2) D
- L 4 (5)
where P1 and P2 are pressures· at two positions
along a pipe of internal diameter D, at a distance
High Frictional Resistance L apart.
Results obtained by Weber2 in a similar manner
Fig. 4--Dewatering of concrete in a pipeline using a laboratory piston rig, by Alekseev5 using
a rotary viscometer, and by Ede using a sliding
compression apparatus,! have also been included
in Fig. 3 for comparison with results obtained by
the authors. It will be seen that although in each
case different methods were used the results are
Dou blc Acting for practical purposes comparable.
Hydraulic Cylinder
The relationship obtained shows that:
1. The flow resistance can be reduced by using
higher slump concretes.
Calibrated 2. For a maximum pump pressure the maximum
Measuring Rod ---11
concrete velocity or pump output is limited by the
flow resistance/velocity relationship.
Top Cop
Summary
The above theoretical concepts have provided
a base for not only developing the dewatering
test described in the following section, but have
also enabled assessment of the value of various
parameters which affect the pumping process,
e.g., admixtures. There may be little value in
using a workability aid to improve the pumpability
of a mix which shows dewatering characteristics.
'o' Ring Bleed
Top The dewatering performance of a pumping mix
t
is not, however, the only factor for defining its
Measuring suitability. Even certain saturated mixes can re-
Bose Cylinder sult in a high flow resistance with too great a
50 Mesh Gauze demand for pumping pressure and can induce
Gauze Retainin severe pump and pipeline wear. Such mixes tend
Plate. to have a high proportion of fine material in the
form of either fine sand or a high cement content.
Fig. 5-Pressure bleed test apparatus (I mm = 0.039 in.) Thus to measure the pumpability of a concrete
mix, two parameters should be measured: (a) the
flow resistance R. The value of V 1 has been de-
permeability or dewatering characteristics, and
fined as follows:
(b) the flow resistance.
s In the United Kingdom for the range of con-
Vt=T cretes and concreting materials generally used, the
where flow resistance values appear not to require high
S = stroke length of the pump pumping pressures. With the more commonly
T = time for a single pressure stroke
occurring coarser aggregates, dewatering is more
likely to be a problem. This has meant that greater
If the piston and pipeline diameters (D 1 and D 2
emphasis has been attached to the development of
respectively) are not equal, however, the velocity
a means of measuring the dewatering characteris-
of flow in the line must be corrected for the
tics than to flow resistance.
change in cross section as follows:
However, it is considered that where necessary,
D1 ) 2
S the use of viscometric methods to measure the
Vt = ( D;- --ry- (4) shear resistance of the boundary layer paste would
The base has a bleed hole drilled into the side 120
and a tap has been inserted. The inside of the PUM~ABLE-
bleed hole is covered by a 50 mesh wire gauze 6 100 r\\
to prevent blockages in the tap.
Procedure
Having locked on the base plate, the cylinder is
filled with concrete to a level about 1.5 em (0.6
..
~
c:
0
u
0 4
0
>
5
..,
~
E 60
.:!
80
v10
!
j~l7
4
·'/7
v
~
---
~ ~-+ --- ~·-
BORDERLINE p. s
NON-PUMPABLE
RESERVOIR
POSITION 2.
0 50 100 150
WATER EMITTED (V 140 -V 10 >ccm 3 )
~
Some typical values of void content for com- 1-
bined aggregate sand and cement are illustrated z
11.1
in Fig. 10. 1-
z
0 0
Application u
CEMENT("/. by wt.of total solids)
As well as measuring the void content of the c
combined solids including cement, it is also useful 0
>
to measure the voids within the aggregate system
alone. By combining the aggregates in such a way
as to produce a minimum voids content, it follows
that to fill these voids a minimum cement content
will be required to produce a concrete which is
sufficiently impermeable for pumping.
Fig. 10 shows the typical effect of varying the
sand content on the voids in the combined aggre-
gate and also the increase in the voids of the total SAND ("/.by wt of total aggregate)
solid particle system when the cement content is Fig. I0-Typical values of void content
increased above an optimum value.
The void meter has been found to be a useful 3No.25mm DIA.STEEL
RESTRAINING BARS
tool for the assessment of aggregates for pump LUMINIUM SHEETING
degree of control over both ready-mixed and site- -4 PAIRS OF ACTIVE ELECTRICAL
RESISTANCE STRAIN GAUGES
hatched concrete. AT 90° INTERVALS (HOOP AND
0 POWER SUPPLY
AND STF\AIN REC.ORDER.
LONGITUDINAL DIRECTION).
Technique
Fig. 11-Details of instrumented pipeline (I mm = 0.039
A method has been developed whi~h may be in.)
used in the laboratory or on site to record in-
directly the pressure of concrete in a pipeline and A strip ~hart pen recorder was used to monitor
thus give an indication of both the pumpability the results, allowing adjustment of the chart speed
and variability of concrete while being pumped. and enabling instantaneous observation of the
The method consists of measuring the line pressure data.
continuously by the strain developed in the short A typical pressure trace is illustrated in Fig. 12,
section of calibrated pipeline. The results are re- showing results obtained using a chart speed of
corded in terms of the voltage change from a 1 mm/sec (0.04 in./ sec). The advantage of having
bridge of electrical resistance strain gages mounted a continuous record of pipeline pressure is that the
on a reduced section of the pipe wall. A section of variability of the concrete may be observed
strain gaged pipe is illustrated in Fig. 11. throughout a pumping operation and immediate
0 2 3
TIME (Minutes)
Fig. 12-Continuous pressure trace (I kgf I em~ = 14.22 psi; I mm = 0.039 in.)
action taken in the event of a tendency towards time" is taken up by the valve change time Tv,
a high pipeline pressure. and also the time taken for the piston to hit the
The recorder, when operated at a faster rate concrete, Tp. The latter part of the dead time Tp
(10 mm/sec) (0.4 in./ sec), provides a range of is related to the design of the cylinder inlet valve
more detailed information including pipeline (i.e., the filling efficiency of the cylinder), and
pressures, concrete velocity, and the efficiency of also the workability of the concrete.
the pump, which may be quantified and ulti- The filling efficiency can be defined by that pro-
mately used in the design of pumpable concretes portion of a piston stroke during which the piston
and improved pumping systems. is in contact with the concrete.
The time for a single piston stroke is (T c/2) -
Analysis of traces Tv; thus the filling efficiency can be defined by
The majority of work carried out in this field the equation:
has been mainly concerned with determination of
pipeline pressures.~ However, from a more detailed
analysis of the pressure traces it will be seen that
Efficiency= [ 1 - (Tc/ 2~P _ T, JX 100 percent
(6)
further useful information may be obtained related
particularly to concrete workability and also the For a particular pump, the value of TP will be
efficiency of the pumping system. A typical pres- directly related to the workability of the concrete,
sure trace obtained using the increased chart being defined by its ability to flow into the pump
speed is illustrated in Fig. 13. cylinder. This is illustrated more clearly in Fig.
The peak pressure P]J occurs when the piston 14. Thus by continuous recording of the pressure
hits the concrete in the cylinder and is the impact traces the variability of the concrete workability
and initial pressure required to move the concrete. may be indirectly observed.
The constant velocity pressure Pcu is the pressure A knowledge of the concrete velocity during
required to keep the concrete in motion. the pressure pulse is of value in investigating
During one cycle (i.e., the time taken for both pumping problems and the influence of, for ex-
pistons to complete one stroke), some of the time ample, admixtures on pumping performance.
is ineffective in moving the concrete. This "dead The transport velocity of concrete in the pipe-
_PEAURESSU~__(pp}_ _ _ line can be estimated using the following equation:
j I
r - -r
.
I Tp
I
I I
i) POOR WORKABILITY ii)MEDIUM WORKABILITY iii)GOOD WORKABILITY
LOW FILLING EFFICIENCY INCREASED FILLING EFFICIENCY HIGH FILLING EFFICIENCY
LOW THROUGHPUT AVERAGE THROUGHPUT HIGH THROUGHPUT
HIGH FLOW RESISTANCE REDUCED FLOW RES I STANCE LOW FLOW RESISTANCE
The value of (To/2) - T, is in fact the value T pumping system has been established which pro-
given in Eq. 4. vides at least a qualitative basis for understanding
Thus it can be seen that by close observation of problems in pumping.
the shape and dimensions of the pressure traces, 2. The pressure bleed test apparatus has been
information not only on pumping pressures but found to be a satisfactory laboratory and site
also the flow properties of the concrete and ef- method for measuring indirectly the permeability
ficiency of the pump may be obtained. of concrete for pumping and, as regards this fac-
tor, provides a method for controlling pump mixes
Application on site.
A number of tests have been carried out using 3. The void measuring apparatus may be used
strain-gaged pipelines. The original flow re- in the proportioning of economic pumpable con-
sistance/concrete velocity relationship illustrated cretes to minimize the cement requirement by ob-
in Fig. 3 was determined using this method and a taining a minimum voids content in the combined
series of pressure traces and associated values of aggregates.
throughput are illustrated in Fig. 15. 4. Recording of in-line pressure/time traces
Further tests have been carried out to measure provides a method for measuring the effectiveness
the effectiveness of additives and modifications to of different types of pumps and improvements to
the pumping system designed to reduce the pump- the pumping process, as well as observing varia-
ing pressure requirements. tions in materials and mix proportions.
The most recent series of tests has been carried 5. By use of the basic theory outlined, and the
out to measure the variability of site-mixed con- test methods described, pump, pipeline, and con-
crete. A strain-gaged pipe was inserted into a
fixed pipeline on site and readings taken on 2 0
three occasions for periods of up to 4 hr. A set
of traces showing the variation in workability is
shown in Fig. 14.
The strain-gaged pipeline has been found to be IIJ
a: 15
a useful tool in the assessment of the factors :::1
1/)
affecting the pumpability of concrete. Further- 1/)
IIJ
more, having overcome the major problems of in- a:
a..
strumentation the results can be used confidently
IIJ
to quantify the effectiveness of various methods of .....
IIJ
improving the pumpability of concrete by vari- a:
u
ation in mix proportions or ·the use of admix- z 5
0
tures. It is also useful as an instrument for quality u
control by continuous recording of pipeline pres-
sures and to assess t'he operating performance of
different types of pumps.
0 2 3 4
CONCLUSIONS Tf ME (Seconds)
1. A model for relating the state of concrete in
Fig .. IS..:_Pressure pulses for concrete placed at varying
the pipeline to the concrete mix components and rates (I kgf I em~ = 14.22 psi; I cu m = 35.3 cu ft)
crete mix performance may be quantitatively es- Taylor Woodrow Research Laboratories, Southall, 1970,
tablished, particularly on site, which hitherto has 50 pp.
not been a practical proposition. 4. Loadwick, F., "Some Factors Affecting the Flow of
Concrete Through Pipelines," Proceedings, First Inter-
national Conference on Hydraulic Transport of Solids
ACKNOWLEDGMENTS in Pipes (Sept. 1970), (The British Hydromechanics
Research Association), Bedford, England, Paper D1, pp.
The authors wish to thank the directors of Taylor Dl-32.
Woodrow Construction Ltd., Southall, England, for al-
lowing the paper to be produced and permitting the 5. Alekseev, S. N., "On the Calculation of Resistance
inclusion of company information, and to the Construc- in Pipes of Concrete Pumps," Mekhanizatziya Stroi-
tion Industry Research and Information Association who tel'stva (Moscow), V. 9, No. 1, Jan. 1952, pp. 8-13 (in
partly financed the initial research program. The au- Russian). Translated as Library Communication No. 450,
thors are also indebted to the former and current per- Building Research Station, Garston-Watford, Apr. 1963.
sonnel in the Materials Laboratory of Taylor Woodrow 6. Kempster, E., "Measuring Void Content," Contract
Construction Ltd. for their contribution to the experi- Journal (Surrey), V. 229, Mar. 27, 1969, pp. 409-410.
mental, laboratory, and site work, and assistance in the
theoretical studies. In particular they would like to
express their appreciation of the efforts of Mr. A. APPENDIX
Flateau, Dr. J. Parkinson, and Mr. F. Loadwick, who
were directly involved in the project during their em-
Saturated or hydraulic flow
ployment in the laboratory. Consider an element of pipe of length d,, and diameter
D, as shown in Fig. A-1. The forces producing a con-
stant velocity V will be the pressure force opposed by
REFERENCES
the resistance to flow. The flow resistance R for hy-
1. Ede, A. N., "The Resistance of Concrete Pumped draulic flow is a function of the fluid properties and
Through Pipelines," Magazine of Concrete Research its velocity. Thus for a constant velocity, the flow re-
(London), V. 9, No. 27, Nov. 1957, pp. 129-140. sistance is constant with respect to pressure and length
2. Weber, Robert, Transport of Concrete by Pipeline of pipe for a particular fluid.
(Rohrforderung von Beton), Beton-Vertrage GmbH, Equating forces across the element for constant ve-
Dusseldorf, 1963. Translated as C&CA Library Trans- locity (i.e., constant volume flow rate):
lation No. 61.129, Cement and Concrete Association, .
London, 1968, 88 pp. D
p.,.T-
2
( dP
P +dx dx
).,.D2
- 4- = R ..Ddx
3. Browne, R. D., and Loadwick, F., "Mechanics of
Pumping Concrete," Research Report No. 014J/70/1450, (A-1)
. D dP D dP
.. R = - - - - - - = A + ILkP
4 dx 4 dx
Separating the variables and integrating over a length
Integrating over a length of pipeline x from the pump, of pipeline, x from the pump,
R
0
! "' -
dx- - D
-
4 Po
!P dP
D dP
- - - =A+ILk
( dP dx)
P+ -- Received Dec. 3. 1975, and reviewed under l·nstitute publication
4dx dx2 policies.