Guide for pumping
lightweight concrete
For trouble-free pumping, keep these points in mind
etter pumps and a better
B understanding of light-
weight aggregate proper-
ties have made it easier to
pump lightweight structural con-
c re t e. But pumping this material
most efficiently still requires a team
approach that involves the design
engineer, general contractor,
pumping contractor, aggregate
supplier, concrete producer, and
testing lab. Each team member
plays a part in a successful light-
weight pumping operation. Here
are suggestions for team members
who design, produce, test, or pump
lightweight concrete.
Design engineer
■ Mixes that are regularly used in a
market area are the most eco-
nomical. Consult the lightweight
aggregate supplier for detailed
mix design information and
material capabilities such as unit
weight and compressive
strength.
■ Specify 4% to 7% entrained air
for pumpability, workability,
finishability, and durability.
■ Specify the maximum size aggre-
gate rather than specifying
individual sizes.
■ Allow higher slump at the pump
to accommodate possible slump
loss.
■ Have the testing laboratory run
design curves based on a slump
within 1 inch of the maximum
permitted and air content within
0.5% of the maximum allowable,
as suggested in ACI 301, Specifica-
tions for Structural Concrete for
Buildings.
■ Specify a pre-pump meeting with
the following present: engineer,
architect, contractor, concrete
producer, lightweight aggregate
supplier, testing agency, admix-
ture supplier, and pumping con-
tractor. Discuss details of con-
crete production, placement by
pump, and inspection. On large
jobs, have the same people pre-
sent during the first pumped con
crete placement.
■ Specify exactly where concrete
should be tested (preferably at
the end of the discharge line as
suggested in ACI 304.2R, Placing
Concrete by Pumping Methods)
■ Realize that water absorbed in the
aggregate does not affect the
water-cement ratio as defined in
ASTM C 125, Standard Terminolo-
gy Relating to Concrete and Con-
crete Aggregates.
■ Water absorbed in lightweight ag-
gregates provides moisture for in-
ternal curing. The water is ulti-
mately lost through hydration
and natural drying, but it takes
about 90 days for the lightweight
concrete to reach minimum den-
sity. More economical mixes can
be used if strength and unit
weight are specified at an age of
56 or 90 days.
General Contractor
■ Keep everyone on the team com-
municating.
■ Use an experienced pumping
contractor.
■ Plan the pump location so two
ready mix trucks can unload at
one time.
■ Designate a laborer to help the
testing laboratory inspector.
■ Provide a washout area for con-
crete trucks.
■ Make use of the concrete truck
radio when placement delays
occur.
■ Tell the concrete supplier how
many cubic yards per hour you
want, not how many trucks.
■ Agree with the concrete supplier
on how the quantity of concrete
delivered will be determined.
■ Use a cement-sand slurry to
prime the pumping system at the
beginning of each placement.
Pumping contractor
■ Know what unit weight concrete
you are pumping.
■ Order concrete for the time you
will start pumping, not the time
your pump will arrive at the
jobsite.
■ Maintain continuous placement.
■ Have the operator know the max-
imum slump concrete that can
be used.
■ Use 5-inch-diameter clean steel
lines and no more flexible hose
at the end of the line than is
needed.
■ To maintain the best perfor-
mance and least slump loss, use
a pump with a piston size as
close as possible to the line size.
■ Use the same pump and opera-
tor for the duration of the job.
Concrete producer
■ Pre-soak lightweight aggregate
prior to batching using proce-
dures recommended by the light
weight aggregate supplier.
■ Check with the lightweight ag-
gregate supplier for recommend-
ed concrete mix design for
pumping and for field correction
procedures.
■ For yield and inventory control,
check the aggregate unit weight
or moisture content every time
bins are filled.
■ Tell drivers when admixtures are
being used for slump control.
■ Maintain a minimum 3-inch-
slump before adding a supe-
plasticizer.
Testing laboratory
■ Field inspectors should be ACI
Field Technician Grade 1 (or
equivalent) in accordance with
ASTM C 94, Standard Specifica-
tions for Ready-Mixed Concrete.
■ Make sure inspectors have the
proper equipment, including a
volumetric air meter and a
strikeoff plate for unit weight
tests.
■ On large jobs, use the same in
spector for all concrete place-
ments.
■ Make sure the inspector knows
minimum and maximum unit
weight limitations.
■ Provide a curing box in a location
that protects cylinders from vi-
bration. Tell inspectors to put
cylinders in the box immediately
after casting them.
Editor’s note
This article is based on information
found in an educational brochure on
pumping structural lightweight con-
crete, published by the Expanded
Shale Clay & Slate Institute. For a
copy of the brochure, write to Expand-
ed Shale Clay & Slate Institute, 2225
E. Murray Holladay Rd., Suite 102,
Salt Lake City, UT 84117.
PUBLICATION#C920096
Copyright © 1992, The Aberdeen Group
All rights reserved