HOW TO SPECIFY AND USE CONCRETE

PUMPLINES
Getting safe and durable pipelines.
By Joe Nasvik

Determining how best to set up a pumpline system for concrete isnt usually the concrete
contractors responsibility; you leave it to the experts. Its one of those details the concrete
pumping contractors usually cover as part of their scope of work. But like everything in
concrete construction, contractors should know the basics for all aspects of the work.
Setting up a pumpline can be as simple as rolling out a small diameter hose on a jobsite and
connecting it to a concrete pump. But it can also be as complicated as placing concrete 1000
feet above ground, running it through bends cast into thrust-blocks, and stand pipes
expanding and contracting several inches per day while being secured to the structure. The
latter requires careful planning.
Closely related to the success of a pumping system is the concrete mix. The mix and the line
must be compatible so placement can proceed in a straightforward manner. Pumping
companies and those who design pumpline systems often have little voice in the design of
mixes; the project requirements for concrete govern that. But communication is necessary

to achieve a good delivery system. Steel pipes, or slicklines, must be the proper size and the
proper type of pipe with the right wear properties in relation to the concrete mixes to
achieve good productivity at the right price.
Safety is always a consideration, too. A plugged line can result in high line pressures, putting
everyone nearby at risk. Safe pumplines involve both the proper design and safe work
practices.

Designing the mix

Gary Brown, operations manager for R.L. McCoy, Indianapolis, says the best concrete for a
job and the best concrete for a pumping operation are sometimes diametrically opposed.
The easiest concrete mix to pump has a high water-cement ratio with as much portland
cement as possible. Water-cement ratios of 0.45 or more are the easiest to pump and using a
superplasticizer to achieve higher placing slump doesnt help much. Pozzolans, however,
can be helpful as a portland cement replacement. But the best concrete for a project may
require a low water-cement ratio and cementitious amounts calculated to increase
compressive strength and reduce shrinkage.
Aggregate is an important consideration in the design of a pumpline. The pipe or hose
diameter for a project should be at least three times larger than the diameter of the largest
aggregate. So for instance, if the largest aggregate in a mix is 1 inch, the minimum diameter
for the line is 3 inches.
Brown says the aggregate gradation of a concrete mix is also a concern. Gap-graded mixes
are more difficult to pump and wear out pumplines (and pumps) faster than well-graded
mixes.
The amount of aggregate in a mix also affects pumpability. According to Brown, a pea gravel
mix consisting of 1100 pounds of coarse aggregate is about all that a pump with a 2-inch line
can handle. If a 1-inch top size aggregate mix is used the approximate total weight of
aggregate shouldnt exceed 1800 pounds/cubic yardaggregate source is an important
factor here.

Designing the system

From their extensive field experience with pumping concrete, most pumping contractors
and concrete contractors are competent to lay out pumplines for typical applications. But
there are many situations requiring expert help.
Residential footing and foundation placements are among the most straightforward. Most
foundations can be pumped directly from a boom truck, making set-up and clean-up simple.
Its important, however, that pump trucks be set up on stable ground, not on uncompacted
fillwhats safe enough to support a truck is not always clear. When pump trucks cant get
close enough, or find stable ground close enough, to place concrete with their booms, lines

must be set up. Foundation contractors often prefer flexible hose instead of slickline for this.
Kyle Rask, director of safety and risk management for Brundage Bone, Kent, Wash., says
400 to 500 feet is about as far as you can reach with a flexible line.
Commercial applications can be more complex. Depending on the experience of the
contractor or pumping company, a pumping consultant is sometimes involved when
specifications are being developed, when contractors are bidding the job, or when its close
to the start of construction. High-rise buildings require the most expertise. John Schantz,
chief engineer for ConForms, Port Washington, Wisc., a supplier of abrasion-resistant
piping systems, says its because on commercial projects, concrete is typically pumped
longer distances and at higher pump pressures.

A word about hose-whipping

Most workers probably arent sufficiently aware of hose-whipping. This phenomenon can happen at the start of
delivery when concrete is first pumped through the line, whenever the line is broken apart and reassembled, or when
the concrete level in the pump hopper gets too low, allowing air to enter the pump. Air introduced into the line is
compressed by the pressure exerted by the pump on the concrete. When this air gets close to the end of the line the
pressure is released in an explosive manner, spraying concrete at high velocity in all directions. Flexible hoses
dangling from a boom or when laid horizontally can whip violently as a result, hitting nearby workers with
tremendous force. The increased efficiency of todays pumps delivers higher pressure and higher volumes of concrete,
increasing the effect of hose-whipping. To see this in actionand gain the proper respect of the dangerwatch
theshort video clip on the American Concrete Pumping Association (ACPA) website.

Projects placing higher concrete volumes require additional planning for pumplines.
Schantz says his company provides pumpline design as part of what they offer a client, with
high-rise projects being a large percentage of this work. One of the first considerations is
how long the pipe needs to last. Lines on big projects can be in place for a long time and
contractors dont want to replace them while a job is in progress. Selecting the type of pipe
to use depends primarily on the amount of concrete yardage involved and the type of
aggregate being usedwear is considerably higher in some parts of the country due to local
aggregates. Pipe wear can be up to five times more depending on a projects location,
Schantz adds. The pressure required to move concrete to the point of placement is also a
factor. In a typical 5-inch standpipe, moving concrete 1 vertical foot requires approximately
1.1 pounds of pressure. Pumping concrete 1000 vertical feet therefore requires a minimum
pressure of 1100 psi.
Once wear and pressure factors are calculated, a decision can be made on the type of pipe.
Brown says pipe is often selected based on its expected life, the goal being to choose pipe
that will last through the project but wear out by the end. The highest wear, highest pressure
pipe is induction heated, single wall pipe and couplings, used for high-rise construction
projects. It can handle pressure up to 5000 psi and beyond.
Twin-wall pipe is the most wear-resistant and is commonly used on boom trucks and
placing booms. But its rated as low-pressure pipe, typically operating at pressures below

1250 psi on booms. The inner layer of this pipe is harder, more brittle steel and therefore
more wear-resistant, while the outer layer is softer and more ductile.
Projects such as high-rise buildings require riser pipelines to be permanently anchored to
the structure for the duration of a project. Pipe bends or sweeps are secured by casting them
through concrete thrust blocks, preventing the pipe from moving due to the forces of the
concrete moving in the line.
Its also common for high-rise projects to include placing booms, often mounted on top of
self-rising core-forming systems. Buildings with larger deck structures may have two or
more placing booms, so included in the installation might be diversion valve systems at
ground level, directing concrete from one standpipe to another, adding to the complexity of
a system.
Designs for pumplines intended to remain in place for the life of a project, such as high-rise
construction, must also include ways to clean the line and dispose of the concrete. A 100foot long section of 5-inch line holds about 1/2 cubic yard of concrete. By the time the One
World Trade Center project in New York City tops out, filling the slickline to deliver
concrete will require about 10 cubic yards of concrete. The usual way to empty the line after
a placement is to include a diversion valve to empty the line back into a ready-mix truck.
Cleaning uses compressed air, blowing out the standpipe from above.

Monitoring line wear

Brown says its difficult to judge wear in flexible line because abrasion to inside surfaces
isnt easily detected. Wear can lead to a rupture, especially if workers inadvertently cause
hose lines to kink, causing pressure spikes.
Monitoring pipe wear is important, so concrete pumping companies like Brundage Bone
and R.L. McCoy have testing programs to monitor wear. Brown says twin-wall pipe wear is
more difficult to judge than single wall pipe. The usual testing devices dont work so visual
inspection and using calipers to measure pipe thickness at its ends is all companies can do.
Most pumping contractors keep yardage records for all their equipment and use the
information to help them decide when maintenance or replacement is necessary.

Safety first or safety second

When placing concrete with a concrete pump and the line plugs up somewhere, the
response is often a frantic one. Everyone scrambles to find where the line is plugged;
breaking sections of hose or slickline apart in the search for the problem location. The
problem needs to get fixed and concrete moving as fast as possible before a plug develops
somewhere else. With flexible hose, workers often jump on the line feeling for hard spots.
They might use sledge hammers to pound on the hose to break up clumps and get the
concrete moving. Its an exhausting, back-breaking effort, working against the clock.

During all this activity there sometimes isnt much thought given to safety. The objective is
more one of fix the problem now, and think about safety later. The better approach is to
conduct safety training sessions, carefully plan for pumpable concrete mixes, make
knowledgable decisions on line design, and have experienced pump operators. All of this
taken together is the proactive way to the best outcome.
When thinking about pump safety, consider the following:
Pumps are built to deliver constant volume. When a line plugs, pump pressure

instantly spikes to the pumps maximum capacity in order to keep output volume constant.
Pump operators must constantly monitor line pressure. When problems arise, line

pressure should be relieved before workers start troubleshooting.

Pipe bends are a point of high wear so frequent inspection is important.

Workers should work with their back to the pumpline whenever possible.

Workers should remain a reasonable and prudent distance away when air is
introduced into a pumpline for any reason. Wait until a steady flow of concrete resumes.
Position a laborer at the hopper when the pump operator is at the point of placement

to be sure lumps, foreign material, and air doesnt get into the hopper due to low concrete
levels.

A small number of project owners still specify unsafe practices, especially regarding
boom pumps. Address any issues before a job starts.

Never attach any metal device to the end of a hose.

Horizontal lines wear much more quickly than vertical lines.

Pumps, especially boom pumps, should be set up on ground as level as possible

and must rest on stable subgrade to avoid the risk of tip-overs.

Pump outriggers should always be fully extended.

Pumps near excavations should be located at least 1 foot away for every vertical foot
of drop.

Workers must have stable footing near hose ends when placing concrete.
The American Concrete Pumping Association (ACPA) suggests that the operator on your job
be ACPA certified. Certified operators must complete an intense ACPA safety training
program that includes special emphasis on the hazards of air getting into the delivery
system (see A Word About Hose Whipping). ACPAs website, has a special Contractor tab
with free downloadable safety information.

Be kind to the line

When we think about concrete pumping we automatically focus on the concrete pump.
There isnt anything romantic about pumplines; they are just a collection of tubes. But
pumplines are the delivery mechanism contractors works with. They are carefully designed
to provide good, safe service with few problems. When all goes well, its natural not to think
about themthats the way it should be.

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