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Some issues related to pumping of


concrete
Bhupinder Singh, S.P
S.P.. Singh and Bikramjit Singh

1
With the establishment of more than 80 not be said about the specifications, capac- tary valves, Fig1 . The operation of the di-
commercial batching and mixing plants ity and selection of pumps to be employed rect-acting pump is rather simple. The con-
set up in metropolitan and other cities in for pumping of concrete. An attempt has crete is fed into the pump by gravity and
been made here to discuss some of the is- partly by suction created due to the recip-
India, the practice of pumping of concrete
sues related to characteristics of concrete rocating motion of the horizontally-acting
is becoming common. In this write-up, pumps so as to enable the reader to make piston, while the semi-rotary valves open
attention has been drawn to the various an informed choice of pumps for pumping and close alternately. Suction pressure of
parameters having a bearing on the concrete. The parameters of interest are
2
the order of 0.08 N/mm is developed in
pumping of concrete with particular pump capacity, power requirements and the pumping cylinder under favourable con-
relevance to the appurtenances involved characteristics of the delivery pipelines. ditions. Best suction conditions are obtained
thereof. The influence of these parameters if the diameter of the suction pipe is the
Concrete pumps have been known for same as that of the pumping cylinder so
on determining the capacity of concrete
more than 50 years. In modern times, large that the concrete can flow unhindered. Con-
pumps has been discussed and an quantities of concrete can be transported crete should be able to flow freely through
example has been presented on by means of pumping through pipelines the full cross section of the suction pipe
calculations for selection of a concrete over appreciable distances, often to loca- and possible blockages due to over-sized
pump for conditions obtained on a typical tions that may not be easily accessible by aggregates should be avoided. Ideally, the
construction site. other means of delivery. The system for
pumping concrete
essentially consists
Recent years have seen a substantial increase
of a hopper into
in the use of pumped concrete, especially
which the concrete is
in infrastructure projects in the country.
discharged from the
Ready-mixed concrete (RMC) suppliers
mixer, which in turn,
have played a major role in popularising
feeds the concrete
the concept of concrete pumping in India.
pump itself and fi-
Invariably, most of the applications are
nally the delivery
concentrated in and around the metros and
pipelines through
it is only lately that the concept and appli-
which the concrete is
cation of pumped concrete is percolating
delivered.
to the mofusil areas where more often then
not, pumped concrete is viewed as an
unaffordable luxury. These skewed percep- Direct acting
tions stem not so much from indifference pumps
as they do from sheer ignorance. More than
A majority of the
enough has been said and written about
concrete pumps are
the characteristics and requirements of
of the direct-acting,
pumpable concrete. Plenty of specialist lit-
horizontal piston-
erature on pumpable concrete1 is available
type with semi-ro-
in the public domain though the same can-

September 2004 * The Indian Concrete Journal 41


Point of View

squeeze pumps are Pumping pressure


also available for
pumping concrete, The maximum pressure, which a concrete
1
Fig 2 . The concrete pump is able to generate, depends on the
from the collecting mechanical design of the unit in question,
hopper is fed by ro- particularly the concrete valves, taper sec-
tating blades into a tions, delivery pipelines etc. Lorry-mounted
flexible pipe con- concrete pumps which invariably have short
nected to the pump- delivery pipelines will require pumps gen-
ing chamber, which erating maximum pressures of around 7
2
is under a N/mm (70 bars). Hence, it follows that a
vacuum of about typical lorry-mounted pump with a 90-kW
2
0.08 N/mm . The prime mover can deliver a maximum of
vacuum ensures 90 × 25
that, except when being squeezed by the = 32.14 m3/h of concrete. If un-
diameter of the suction pipe should be at 70
rotating rollers, the pipe shape remains cy-
least three times the maximum size of the der certain circumstances, a pumping pres-
lindrical and thus permits a continuous
aggregate in the concrete to be pumped.
flow of concrete. The two rotating rollers sure of say 4.5 N/mm2 is deemed enough
The diameter of the suction pipe therefore for the above unit, then a peak output of
mounted on planetary drives progressively
controls the maximum size of aggregate,
which can be used in a given mix of con-
squeeze the flexible pipe and thus push the 90 × 25 3
concrete into the delivery pipe. Outputs of = 50 m /h of concrete can be ob-
crete to be pumped. 3 45
up to 20 m /h can be obtained with squeeze
tained. Therefore, it follows that the pump-
During the ‘suction stroke’ the inlet- pumps using 75-mm diameter pipelines.
ing pressure and the peak concrete output
valve opens and concrete is admitted into Squeeze pumps may be lorry mounted and
are inversely proportional to each other.
the pumping cylinder, the outlet valve re- deliver concrete using a placing boom.
Portable concrete pumps which may place
maining closed. In the ‘delivery stroke’ the Squeeze pumps can transport concrete up
concrete at horizontal distances of up to
outlet valve gets opened and the inlet valve to a maximum distance of 90 m horizon-
1000 m or vertical distances of up to 400 m
being closed, the concrete gets pushed into tally or 30 m vertically. Due to the cumber-
may require pumping pressures of the or-
the delivery pipeline. The concrete moves in some mechanics of squeeze pumps, direct 2
der of 20 N/mm (200 bars).
a series of impulses, the delivery pipe al- acting pumps find greater field applica-
ways remaining full. Outputs of up to 60 tions compared to squeeze pumps. To be able to achieve a targeted output
m3/h can be achieved in modern pumps of concrete at site it is imperative to
through 220-mm diameter delivery pipes. Criteria for selecting a determine as accurately as possible the
required pumping pressure so that together
Conventional pumps are equipped with an concrete pump with the desired concrete output, a rational
agitator in the feeding hopper. The agitator
maintains the flowability of the concrete and The two primary parameters, which should basis for selecting a pump can be developed.
prevents the setting of the concrete or build- be known prior to selection of a pump, are The volumetric output of concrete desired
ing-up of aggregate bridges across the open- the maximum desired volumetric output would depend on the type of job at hand
ing of the suction pipes. In case the pump of concrete per hour and the peak pumping and the desired progress of work. The
is required to be shut down temporarily for pressure, p. A nominal output of 30 m3/h primary variables on which the pumping
some reason it may be possible to remix the is considered sufficient for routine concret- pressure is dependent can be listed as the
concrete at the commencement of pump ing operations related to most civil engi- total lead, delivery pipeline diameter,
operations using the agitator. neering applications. For specialised jobs delivery output, concrete consistency and
where greater output is desired, pumps directional changes in the pipeline. The
Direct-acting concrete pumps may be with a capacity in excess of 120m3/h have pumping pressure decreases from a
static or portable, in the latter case the been known to be deployed. The required maximum at the concrete pump to zero at
pump can be mounted on lorries. Lorry- power of the drive unit (prime mover) of the output end of the delivery pipeline.
mounted concrete pumps operate with the concrete pump depends on the desired
delivery output of concrete, Q, and the The maximum lead will include the
relatively shorter delivery pipelines. The
pumping pressure, p. The delivery output total maximum horizontal and/or vertical
pump feeds concrete to the delivery pipeline
and the pumping pressure are co-related distance over which the concrete is to be
attached to a hydraulically-maneuvered
by the expression for the hydraulic output, pumped. The maximum lead in terms of
articulated telescopic arm known as the
H, of the concrete pump: the horizontal and vertical placing distance
placing boom. The pipeline length thus
has to be calculated by taking into account
corresponds to the horizontal reach of the
placing boom. Using direct acting pumps, H = Q × p = constant likely increase in the pumping distance due
to bends and directional changes in the
concrete can be readily pumped up to
If Q is expressed in m 3/h and p is delivery pipe. Directional changes in the flow
distances of 450 m horizontally or 50 m
expressed in bars (1 bar = 0.1 N/mm2) and of pumped concrete will undoubtedly place
vertically. For larger distances, relay
assuming a system efficiency of 75 percent, excess demand on the pumping unit and
pumping using pumps in series may be
the required power, P, of the drive unit these are accounted for by adding an
adopted.
(prime mover) of the concrete pump can be equivalent horizontal length of the pipeline
expressed in kilowatts (kW) as : for different types of pipe bends.
Squeeze pumps
Besides direct-acting pumps, smaller port- H Q× p One of the established manufacturers
P = =
able peristaltic type pumps, called as 25 25 of pumping equipment recommends that,

42 The Indian Concrete Journal * September 2004


Point of View

independent of the pipeline diameter, 90- connect individual pipe lengths. A 100-mm observing pumping pressures. The concrete
degree bends with a radius of 1 m may be diameter pipeline is considered ideal for pump is thus one of the greatest aids to
replaced by an equivalent horizontal short and medium placing distances (up quality concrete; it acts as a silent quality
pipeline length of 3 m2. Hence, a 30-degree to 200 m) and concrete outputs of up to control equipment refusing to handle any
bend with a radius of 1-m is equivalent to a 25 m3/h. For longer placing distances and concrete which is unduly harsh,
length of 1 m. If for example, bends totaling higher outputs, 125-mm diameter pipeline inadequately mixed, non-cohesive and not
630 degrees are installed in a pipeline is considered to be the best and this pipeline correct in consistency4. Pumpable concrete
system, then the equivalent length can be size is considered to be ideal for most site requires sufficient amount of fines, enough
applications. Pipelines of 150 mm diameter slump (about 80 to 100 mm), continuous
630
computed as = 21= 21 × 1m = 21m. are generally used for placing concrete with grading of aggregates and uniformly and
30 a maximum aggregate size greater than thoroughly mixed materials.
For 90-degree bends in delivery pipelines 40 mm or for placing large quantities of
mounted as for example, on placing booms, concrete at longer distances. Relatively It is to be appreciated that if it is desired
a radius of 0.25 m is usually adopted2. The larger pipe diameters result in lower that pumping is to be carried out at the
equivalent length for such elbow bends is pumping pressures and reduced power rate of 40 m3/h, a concrete pump with a
recommended as 1 m 2. Therefore, the requirements of the prime mover though at maximum pumping capacity of 40 m3/h
horizontal pumping distance for a placing the cost of reduced maneuverability of the can achieve the desired output only if it
boom will be its outer reach plus the pipe network. works continuously for one hour. This is
equivalent lengths for each of the 90-degree seldom the case in view of conditions
bends in the three articulated sections The consistency of the concrete mix has obtained at construction sites. Actual
usually found in placing booms. an important bearing on the pumping pumping time may be 45 minutes or even
pressure. A slump between 40 and 100- lesser. Taking an actual pumping time of
The vertical pumping distance is say 45 minutes into account, if the pump is
accounted for by adding a pressure mm or a compacting factor of 0.90 to 0.95
or Ve be time of 3 to 5 s or concrete within to achieve a nominal out put of 40 m3/h, it
increment of approximately 0.025 N/mm2
(0.25 bars) for every metre difference of the consistency range K3 is generally 45
recommended for the mix in the hopper1,3. must be able to place = 60 m3/h. The
elevation to the pumping pressure 0.75
computed for the horizontal placing The right consistency of the concrete mix is
essential to avoid excessive frictional actual pumping time of 45 minutes in this
distance. illustration can be represented in the form
resistance in the delivery pipe due to stiff
mixes or segregation with too wet mixes. of a ‘work factor’ for the concrete pump
For a given output of pumped concrete,
Stiff concrete is difficult to deform and which in the above case works out to be
the flow velocity and hence the flow
resistance increases with reducing delivery requires higher pumping pressure to pass 45
through bends and tapered sections in the = 0.75 2 . It is reasonable, for the
pipeline diameter as does the associated 60
pumping pressure. For the purpose of delivery pipeline.
conditions typically prevailing in sites, to
illustration, for a nominal concrete output take a work factor of 0.75 to 0.80 while
of 40 m3/h, as the delivery pipeline diameter It may be noted that any variation in
mix consistency or workability can easily ascertaining the actual capacity of a
decreases in the order 150 mm, 125 mm, concrete pump.
112 mm and 100 mm the corresponding be detected at the pumping point by
flow velocities increase in the order
0.6 m/s, 0.8 m/s, 1.1 m/s and 1.39 m/s,
respectively. To limit the pumping pressure
and to minimise pipeline wear and tear it is
always advisable to use larger pipeline
diameters whenever higher delivery outputs
are desired. The difficulty with pipelines of
larger diameter is that they are difficult to
handle, especially when they are filled with
concrete. Both rigid and flexible pipes can
be used for pumping concrete though rigid
pipes are more popular because of the
additional frictional losses and cleaning
problems associated with flexible pipelines.
Rigid pipelines made of steel are available
in varying lengths and wall thicknesses.

Individual delivery pipe lengths are


available in lengths of 1 m, 2 m or 3 m with
the most common wall thickness of the
pipes for the range of pumping pressures
usually employed (7 to 10 N/mm2) being
4 mm. For higher pumping pressures
(20 N/mm2 and more) pipes with wall
thickness of more than 7 mm are usually
recommended. Quick-locking couplings

September 2004 * The Indian Concrete Journal 43


Point of View
Required concrete output (given) pump with specifications nearest to the
3
= 40 m /h desired ones can be selected, Fig 4.
Work factor (given) = 0.75 Conclusion
Slump of concrete (given) = 100 mm The influence of various parameters related
Delivery pipe line diameter (given) to concrete characteristics and mechanical
= 125 mm appurtenances on the pumping of concrete
have been presented. The concrete output,
40
Nominal concrete output = Q = concrete consistency, horizontal and verti-
0.75 cal lead and the diameter of the delivery
= 53.3 m3/h pipeline have an important bearing on the
Delivery pipeline horizontal pumping pressure, which is a critical de-
length (given) = 110 m ...(a) sign parameter. The required power of the
pump prime mover can be estimated from
Number of 90 degree bends = 5; Angular the desired concrete output and the pump-
measure of 90 degree bends = 90 × 5 = 450
o
ing pressure.
Number of 30 degree bends = 2; Angular
References
measure of 30 degree bends = 30 × 2 = 60o
1. N EVILLE , A.M. and B ROOKS , J.J. Concrete
o
Total angular measure of bends = 450 + Technology, Longman, England, 1994 ed. p. 438
o o
60 = 510 2. E CKARDSTEIN , K.E.V. Pumping Concrete and
o Concrete Pumps, Friedrich Wilhelm Schwing
Number of equivalent 30 bends
GmbH, Herne, Germany, 1983, p. 133.
Fig 4 The transit mixer in the fore- 510
= = 17 3. ______DIN 1045, Beton und Stahlbeton bau
ground discharges concrete into the 30 Bemessung und Ausfuehrung (Plain and Reinforced
lorry mounted concrete pump in the Concrete: Design and Construction), German
background (Note: The articulated telescopic Equivalent horizontal pipe lengths Standards Institute, Berlin, December 1988.
at 1 m for each 30 bend = 17 × 1 m
placing boom delivering concrete to the desired o

location) 4. ______Hand Book of Ready-Mixed Concrete,


= 17 m ...(b)
Published by The Cement Manufacturers’
Horizontal reach of placing boom (given) Association, New Delhi, 2002.
In conclusion, the selection of a concrete = 27 m ...(c)
pump for a given job will depend primarily Equivalent pipe length due to standard
on the desired concrete output, the Mr Bhupinder Singh started
bends in placing boom (assumed)
consistency of the concrete to be pumped, his professional career as a
= 10 m ...(d) design engineer with Gammon
the maximum lead in terms of the
horizontal and vertical placing distance and Total equivalent horizontal pipe length India Ltd, New Delhi and sub-
the diameter of the delivery pipeline. Once = (a) + (b) + (c) + (d) = 110 m + 17 m + sequently shifted to academ-
all these parameters are known, the problem 27 m + 10 m = 164 m ics and has taught at Birla In-
stitute of Technology and Sci-
reduces to determining the pumping From the nomogram in Fig 3, for ence, Pilani and Regional Engineering Col-
pressure. Knowing the peak pumping 53.3 m3/h concrete output, concrete slump lege, Jalandhar. He has a keen interest in the
pressure and the desired output of concrete, 100 mm, delivery pipe line length 164 m analysis, design and detailing of reinforced
the power of the pump prime mover can be and pipeline diameter 125 mm, the concrete structures.
determined, as is illustrated with the help pumping pressure works out to be 34 bars
of the following example. Dr S.P. Singh is an assistant
(3.4 N/mm2).
professor in the department of
civil engineering, National In-
Example on pump Vertical lead = 65 m + 4 m = 69 m
stitute of Technology
selection Equivalent static pressure due to vertical Jalandhar. He holds a Ph.D.
lead of 69 m at 0.25 bars (0.025 N/mm )
2 from the University of Roorkee
It is required to place an average of
in the area of fatigue behav-
3
40 m /h of concrete at a multistoried build- per metre difference in elevation = 0.25 × 69
2 iour of concrete structures and maintains a
ing construction site. A placing boom with = 17.25 bars (1.72 N/mm )
close interest in the behaviour and design
a horizontal reach of 27 m distributes the of reinforced concrete structural elements.
concrete. Work factor for the concrete pump Therefore, maximum pumping
may be assumed as 0.75. The length of the pressure = ρ = 34 + 17.25 = 51.25 bars, say Mr Bikramjit Singh is a me-
125mm delivery pipeline with 5 bends of 52 bars (5.2 N/mm2). chanical engineer by training
90 degrees and 2 bends of 30 degrees is and is presently serving as a
Hence, required power of pump deputy general manager
110-m. The maximum height of the build-
ing is 65 m and the end of the placing boom Q× p 53.3 × 52 (plant & equipment) with
= = ≈ 110 kW or say Punj Lloyd Ltd, New Delhi.
is approximately 4 m above the pouring 25 25 He has extensive experience in
point for the top most floor. The concrete 140 HP. the procurement, erection, operation and
slump is 100mm. For determining the re- maintenance of heavy construction equip-
quired pumping pressure and hence the Knowing the required power of the
ment with particular emphasis on concrete
prime mover capacity of the concrete pump prime mover, the required concrete output
pumping and slipforming systems.
the following steps are suggested. and the maximum pumping pressure, the
•••

44 The Indian Concrete Journal * September 2004

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