Concrete Society Digest No.

Pumping concrete
Prepared by: Laing Design and DevelopmentCentre

This digest gives details of the benefits and the special

considerations needed on site for pumping concrete,and basic
information on equipmentand appropriateconcretemix design.

Benefits of pumping concrete

Pumping is an efficient means of transporting concrete in a

steady flow from a mixeror delivery point directly to where it is
required on site, removing the need for barrows, dumpers,
hoists, cranes, etc.
It is especially useful for placing concrete where access is

difficult by other means.

Being under cover in the pipe,concreteis protectedfrom the
effects of bad weatherduring transport.
Generally a gang size of only three or four men is required to
place the concrete, reducing labour costs which would be
required for other means of placement(see Table 2).
Concrete placing rates are maintained up to a maximum
height in high rise construction,whereas the production rate
reduces with height usingother methods. Also, labour costsfor
placingare not increased with height,and savings in the use of
cranes can be an important factor.

Special considerations
Figure 1: A pump with boom-supportedpipeline.

Table 1: Pump comparIson.

Mechanical

or 2

Hydraulic

1 or 2

Cylinders

Weight

Heavy

Dependson size

Mounting

Skid, trailer

Skid,lorry or trailer

Mobility

Usually mobile,

Usually mobile,

flexibledischarge

flexible discharge

Large volumes,
long distances

Average contracts
where sufficientsize
of pours, difficult
access, largesingle
pours

Maximum
pumping
rate

23 m3Ih

70 m3/h, depends on

Typical
pipeline
diameter

75 mm

Use

pump size, distance,

height, etc.
100125 mm, but
can be smaller or
larger

Maximum 150 m horizontal

distances 30 m vertical

400 m horizontal
100 m vertical

Flow

Steady

Pulsating

Concrete mixes may need to be specifically designed to be

suitable for pumping. Mixes specified by the client may not
always be suitable.
For successful pumping, site organizationand planning must
be suitably geared, with close liaison betweensite management,
concretesupplier and concrete pumping company to ensurea
well regulated supply. Long delays can lead to blockages in the
pipeline,which may be difficult to clear,causing further delays.
The faster pouring rate of concrete may require more
formwork and vibration equipment to maintain continuity of
placing.

Economics of pumping
Pumping concrete can be economical in many circumstances,
and can be considered for the whole range of pours from 5 to
5000 m3.
Savings due to reduced construction time are often greater
than savings due to reduced handling costs. Other factors to
consider may include dismantling, maintenance, attendance,
and hire of other equipment such as cranes, formwork and
vibrators.

Types of pump available

The most commonlyavailable pumps are piston typeswith twin
cylinder and mechanical or hydraulicdrive.
Mechanicallydriven pumps
Mechanically driven pumps are the simplest type but they are
relatively heavy. They are often mounted on skids and, being

difficult to handle, they are mainly operated from one position

for long periods,usually standing on a reinforced concretebase

slab. They are bestsuited to pumpinglarge volumesof concrete

over long distances where only limited flexibility is required at
the discharge end.
The pumpsare poweredby an electric motor or diesel engine
to give a maximum output of 34 m3/h for twin cylinder models.
Using 180 mm diameterpipelines, it is possible for concreteto be
pumped up to 450 m horizontally, or 40 m vertically.

Hydraulic pumps
The most commonly used pumps are hydraulically operated.
They are lighter than mechanical types and can be lorry
mounted. They are therefore highly mobile and are used for
many jobs in building and civil engineering. The use of quick
release couplings enables rapid assembly and dismantling,and
most lorry-mounted pumps are equipped with articulated
booms with permanently rigged pipelines which can reach to
heightsof up to 36 m without theaddition of extra pipeline. The
most common diametersof pipeline used are 100 and 125 mm.
However,small diameters of 75 mm or less can be used in highly
congested situations. For diameters of less than 75 mm, an
aggregate size of less than 20 mm may be required.
Hydraulic pumps are smoother in operation than the
mechanical types. They impart a steady speed and consequently
steady pressure to the concrete,thusavoidingthe high pressure
peaks inherent with mechanical drive. They are therefore less
likely to suffer from blockages.
The combination of smootheroperationand higher velocities
in small bore pipes improves the vertical pumping distance to
about a quarter the horizontalpumpingdistance as compared to
only a tenth for mechanical pumps. Vertical pumpingheightsin
excess of 300 m can be achieved in very special circumstances.
Hydraulicoperation has a furtheradvantage in that pumping
rates can be controlled from zero to maximum by varying the
delivery of the hydraulic drive pump. Outputs as high as
125 mi/h are claimedfor the larger twin cylinder models.
In practice, outputwill be highly dependenton factors such as
available labour, pumping distance, height, pumpability of the
concreteand continuity of concretesupply. Outputs are usually
less than those quoted by manufacturers for pumping
equipment.

Concrete suitable for pumping

Resistance to pressure

When concreteis pumpedit is subjected to pressureswhich may

be as high as 10 MN/rn2 (110 bar).
To pump any mix the force exerted by the pump must
overcome the friction between the pipeline and the concrete,
the inertia of the concrete in the pipe, the resistance of the
internal componentsof theconcreteto re-adjustments at tapers
and bends, the energy used in changing direction and the
pressure due to the head of concretewhen placinghigher than
thelevel of the pump (see Figure 4). Pressuremust be transmitted
by the concreteand since only water is naturally pumpable, it is
the water in the mix that transmits the pressure.
To meet these requirementsthe concrete must be cohesive
with aggregate voidscontent reducedto a minimum in order to
reduce segregation and bleeding (see Figure 5).
Materials

The selection of materials is always subject to availabilityand

economicrestraints, butto ensure uniformity of mixedconcrete
and increased flexibility at the concrete design stage it is
advisable to select coarse aggregatessuppliedas single sizes and
to be selective in sand source and grading.
The sand requirementsfor a pumpableconcreteare similarto
the optimum sand content for a given cement content and

cylinder
discharging

cylinder
charging

valve closed

valveopen

hopper

hopper

valveclosed

valve open

output
Figure 2. A typical twin cylinderhydrau(icmobile
pump.

CumulativeO/
wateremitted

.1.

.J

30

40

.1
50

Time seconds
Figure 3. Comparative curve for the bleed test to
determine the pumpabilityof concrete.
Concrete under investigation is placed in a specially
designed cylinderandpressurized. The rate at which
waterbleeds from the concrete is then measured and
plotted on a graph. The resultingcurve is compared
with Figure 3 and, it lies in the centralzone,
probably indicates that the mix will be pumpable. If
the curvelies outside the 'pumpable'zone the mix
can be redesigned accordingly.

if

aggregate/cementratio. Resistanceto bleedingand segregation

can be improved by increasing the proportion of materials,
including cement,which passes a 600 pm sieve. Too muchof this
fine material, however, will cause an increase in frictional
resistance in the pipeline and would require a greaterforce to
pump the concrete.An increased pressure in thepipelinein turn
ristanceR increasesthe tendency to segregation, so the aggregate grading
is an important factor in pumpability.
For trouble-free pumping the concretedeliveredtothe pump
must be of consistent quality. This is especially necessarywhen
high strength concretes are beingpumped.Once theaggregates
have been chosen and the mix designed,allsubsequent supplies
water and fine fines
should come from the same source. If a new source is used, the
act as lubricant
mix may need to be redesigned.

pressure
P

friction F
Figure 4: Representation

of plugflow.

Concrete mix design

A specialist in concrete mix design for pumpability should be

For concrete to pump:

consulted.

P>R+F
where

pump pressure

A = resistance i.e. pressure due to head of

concrete, inertia of concrete in pipe,

resistance to internal readjustment, energy to

change direction
F= friction between pipeline and concrete
but as P increases, F increases

Cementcontent
High

The first requirement is usually compressive strength. Mix

design should be carried out on this basisaiming for a slumpof
about 75 mm. Checks for pumpability should then be made to
ensure that the voids in the combined aggregates are less than
25%. Thiscan often be done by adjusting the proportion of fine
and coarse aggregate. A sieve analysiswill have revealed if the
aggregates are deficient in any particularsize.
itmaybe necessarytoadjustthegradingcurvesby the addition
of new material or to select differently graded aggregates.
Gradingcan be checked against typicalgradingcurvesor against
grading curves known to give good pumpable mixes for the
strengths concerned.Leaner mixes especially will require about
1520% of fine aggregate to pass through the 300 pm sieve.
The BuildingResearchEstablishment has developeda method
of measuring the voids ratio of aggregates11.
The cement content of the mix should be sufficient to fill the
voids and may need to be ratherhigher than forequivalentnonpumpedconcrete,dependingon thecontent of 'fine fines'irithe
sand.

Figure 5: Adjustments to producepumpableconcrete

mixes. The general relationshipbetweencement
content, aggregate void content and excessivefriction
or segregation and bleeding.

Admixtures and additivesto improve pumpability

If it is found that a pumpable mix is hard to obtain by these
procedures, the use of an admixture or additive may be the
answer, but this should normally only be consideredafter full
investigation into the factors involved.
Thickening agents such as polyethyleneoxide additive have
been found to be the most successful for overcoming
segregation. Air-entrainingagents can increase workability and
reduce pipe pressure but should notexceed a dose givingmore
than about 4% air content by volume. The mix design may
require adjustmentto accountfor compressive strength lossdue
to air-entrainment. In long pipe lengths the air content can
absorb the compressive force needed to keep the concrete in
motion, and blockage can occur.
Plasticizing admixturescan be useful in certain mixes to give
greaterfluidity, but in mixes with high voidscontent and prone
to segregation these plasticizers may make matters worse rather
than better.

If frictional resistance is excessive:

Site planning and organization

Low
Low

High

Aggregatevoid content

1.
2.
3.
4.

Decreasecement content.
Adjustaggregate coarse/fine ratio to increase voids.
Increase water content.
Use 'wetting agent' admixture.

If segregation and bleeding are excessive:

1.

2.
3.
4.

Increase cement content.

Adjustaggregate coarse/fine ratio to reduce voids.
Add fines (e.g. rock dust or pfa).
Use 'flocculating agent' admixture.

Adequate site planning and organization are essential for

successful pumping.
The concretesuppliermustbe informedthat the concreteisto
be pumped and that consistency is therefore paramount.
The pump operator and the ganger or foreman in charge of
placing must be in close communication.A radio communication system is often used especially for long distances, difficult
access or where several placing points are in operation at one
time.

The site should arrange for regular slump checking on the

concrete being supplied.
The daily maximum pump utilization is normally6 hoursa day
working at two thirds its maximum rated output. For a pump
rated at, say, 80 ms/h, daily output expected would be about

o 0.
0

--

320 m3 maximum.

42%

COG,

It is a good practice to allow for a stand-bypump on large and

a,

CO

important pours.
For pumping over very long distances or when pumping to
great heights, twopumps may be required. Twopumps working
at optimum pressure are better than one pump working at

maximum pressure.
With some machines, the remote control fitted enables safe
and efficient working of the pump with the pump operatorup to
40 m fromthe pump itself. This enables the operatorto be better

positioned on the site to ensure correct placement of the

concrete.

If a booster pump is required at high level,allowfor suitable

support scaffolding,noting that the effects of vibration must be

adequatelycatered for.
Subcontracting of concrete pumping
Concreteis usually pumpedon site by specialist subcontracting
companies. They charge on an hourly, dailyor weeklybasis,with
a fixed travellingcost to and from site. A minimum hire period is
usually specified.Some companies are associated with, or liaise
with, ready-mixed concretesuppliers and assist in organizingthe
supply of the concrete. However, the final responsibility for
concrete quality still remains with the main contractor.
Site management usually supplies labour for pipe handling,
cleaningout and concrete placing. The responsibility for other
requirements such as moving pipelines, supply of water, air,
grout, etc., will be agreed between site management and the

subcontractor.All requirementsfor cleaningoutafter pumping

must also be agreed.
Mostsubcontractingconcretepumpingcompanies use pumps
which can place concreteat variable rates up to 120 m3/hr.
Concrete supply
The pipeline must first be lubricated by passing a grout mix
through it before pumping the designed concretemix. This is to
form a lubricatinglayer so that fines are not extracted from the
mix.

A steady supply of concretewill be neededto suittheplanned

pumping rate and size of pour.
Ready-mixed concrete is usually the best way of supplying
large volumesof concrete in a relatively short space of time.
All thepumps are fittedwith hoppers into which concretecan
be discharged directly. The hoppers are generally fitted with
mechanical agitators to divertconcreteto the cylinder ports and
to keep the hopper contents agitated if pumping is held up.
Wherever possible, the tailings from one truck should be mixed
with fresh concretefrom a second truck to avoidsharpvariations
in quality.
Large volume pumping may require a reserve source of
concrete supply.Confirm the concreteonlywhen the machine
has arrived, as it may have experienced delays.
A wet storage hopper is used when pumping directly from
under the batching plant.

CO

x
CO

0
Waiting for
concrete

.0
Remixln on site
Workability wrong
Blockages

4%

Postioning trucks

10%

3%
3%

0)
0-

0
CO

C.)

Delay due to late

orderfor final quantity
of concrete

13%

Delay by placing gang

1/o

8j

Moving pump or pipes

Figure 6: Typical analysis of time spent in pumping

operations.
Table 2: Examples of gang size.

Labour requirement for typeofjob

Responsibility
of man

150200

mm

thick Suspended

Large 1 m thick
raft
column
foundation

slab.
Tamped

finish

Control input
to pump
Control pump
Extend and
inspectpipeline

Direct output

23

10

25

Vibrateconcrete
Distribute and

finish
Placing rate m3/h

(for tamping)
2025

Pumplocation
Position the pump or pumps so that pipelines are as short as
possible, need as little repositioning as possible, and are as
straight as possible.

The location must have easy access for delivery trucks, on

made up or well made site access roads. Ensurethereis enough
space for outriggers for vehicle-mounted pumps. The area
should be capable of accommodating two truckssothat theycan
both discharge at the same time if required (see Figure 7).

0
0
0a,

Figure 7: Pumpingconcrete for bridge foundations

with a 22 m boom pump. One ready-mixedconcrete
truck is discharging its load witha second truck
waitingalongside.

The pump and thedischarging trucks should stand reasonably

level on firm ground.
Although most pumps carry their own supply of clean water
for the pump flushing system, and for general cleaning, it is
helpful if a supply is available on site.
It is usual to provide an area away from the access roads and
pumping positions which can be used for washing down
concrete delivery trucks after discharge. The area must be
suitably drained. Washing out can takeplaceoff site if required,
providing it is organized, i.e. high Street contracts cannot be
cleaned there.

Figure 8: Two men controlling the pipeline while a

third compacts the concrete.

Table3: Reduclion of effective pumping distances dueto bends.

Angleof bend

90
450

30
22.5

'pump

Equivalent
horizontal
distance, m

Equivalent vertical
distance, m

12

0.7
0.5

6
4

relief valve

cut off valve

Figure 9: Pumpingdownhill.

The pipeline
Arrange for all pipes, other than fixed booms, to be either
horizontalor vertical.Theconcretein thepipemaytend to bleed
and, if the pipes are inclined, the water will tend to run down
whenever movementstops. Thiswill cause the concreteto lose
water at the top and a blockage may occur.
Gravity assists the pumping of concrete downhill but air
pockets may form at the highest point of the pipeline as the
concrete falls away from it. Include slight bends in the line to
increase reistance and, where possible, slope the pipeline
upwards a little at the end of the descending section.
Sometimes, particularlywhen large volume pumps are used at
full load, pipelines need to be anchored at bends to restrict
movement. These pulsating movements must not be allowed to
affect the formwork or reinforcement.
Pipes should never be added. Pipework should always be
broken back towards the pump, starting at thefarthestpointfirst
and finishing close to the pump. Pipes removed during
concretingmustbe cleared of concreteand cleaned. Inspection
of all joints for grout leaks is carried out while the pump is
running and again when pumpinghas stopped for the day,by the
pump operator.
If the pipeline is uncoupledat any pointto pump to another
placing point, make sure that the concrete remaining in the
unused pipe beyond the joint is not allowed to harden. Do not
uncouple anypipeline without the pump operator'spermission.
Pumping

If

in hot or cold weather

pumping is carried out in hot sunny weather protect the

pipeline with damp sacking or straw mats to prevent
overheating. Continue pumpingallthe time,wait no longerthan
about 10 minutes. The pump should be moved 10 to 12 strokes
about every 5 minutes. Never let the pipeline empty.
At low temperatures, down to about 5C, heat loss through
the line is negligible and heated concrete can be placed quite
quickly without much loss of heat.
Additional checks for pumps using boom-supportedpipelines
A pump using a boom-supported pipeline is often the most
satisfactory solution for small high speed pours.
The boom is usually carriedon the samechassis asthepump to
form a compact unit. Booms are generally folded hydraulically.
These can usually slew and luff so that concrete can be placed
directly where access is difficult. Boom-supported pipescan be
connectedto conventionalpipelines to extend the delivery.
Although a pump can start pumpingwithin lOor 15 minutesof
arrivingon site, it needs good access to get close to the structure
and it is best to allow 30 minutes for setting up.
Arrange scaffolding so that it does not restrict movementof
the boom.
Make sure that overhead electric cables and similar
obstructions will not interfere with the operation of the boom.
If the boom is keptflat to reducepumpingpressure the flexible
end may drag over screeds and reinforcement. The boom
operatorshouldaim to keeptheboom highso that thedischarge
end is only just in the pouring area.

Discharge

Arrangeto work fromthefurthestpointback towards the pump

so that thesections of pipe are removed ratherthan addedasthe
pour proceeds.
A flexible pipe full of concrete may need two men to

It can also damage screeds and may move

reinforcement if dragged over it.
If a flexible discharge pipe is not used, the discharge point
should be at a height sufficientto allow distribution of concrete
without having to shortenthe pipe toofrequently or disconnect
manoeuvre it.

lengths.

Ideally,the first 200300 kg of mixed groutand concreteused

for lubricating the pipeline should be discarded, but this is
sometimes difficult in practice, particularlywith a fixed pipeline.

When concretingwalls and columns, better compaction and

finish are obtained by keeping the delivery hose immersed
500 mm just beneath the level ofthe topofthe concreteas it rises
and vibrating the concrete with immersionvibrators.
Blockages
Blockages should not occur if the foregoing precautions are
observed. If, however, the pipeline does become blocked the
pump mustbe stopped immediately. Occasionally, reversing the
pump for a few seconds will clear the fault.
A blockage can be located by slightly opening pipejoints one
ata time and then pumping slowly, but no couplings should be
loosened or removed unless the pressure in the pipeline has
been released and this is confirmed by the pump operator. If
groutleaks fromthejoint, the pipe is clear from that point. When
the joint does not leak grout, the blockagehas been located.
All blockage location operations must be undertaken under

14

1.

10

iIiIiI1iiIii:

Figure 10: Typical working range ofa pump with

the control of the pump operator, and be carried out in boom-supportedpipeline.
accordance with the BCPAAdvisoryCode for safety in concrete
pumping2.
Blockedpipes must notbe heatedin an attemptto emptythem
of set or partiallyset concrete.
Some blockages may be cleared by shortening the pipeline,
thus reducing the resistance in the line.
Theuse of compressed air for removinga concreteblockageor
for cleaning a pipeline is not recommended unless undertaken
by experienced personnel. Guidance on the use of compressed
air is given in the BCPA AdvisoryCode.
If a blockage cannot be removed after location it may be
necessaryto removethe section of pipeline and replace it with a
new section, wetted and grouted prior to re-startingpumping.
It is not possible to specify a time limit for concreteremaining
in thepipeline ifa blockage cannotbe located or removed easily,
as this depends on the weather conditions, temperatures, and
mix design. Concrete should be removed before the initial set
has taken place. Failing this, the pipeline should be dismantled,
emptied, re-assembled and grouted, prior to re-starting. This
should not be necessaryif the operation of blockage locationis
carried out correctly.
Take care that the pipe has sufficientgroutin itto lubricatethe
concrete when pumping re-starts. If the concreteis allowed to
dryit will causeyet another blockage. If a long pipelinehasto be Figure 11: The numbers indicate the order of
broken and re-assembled, it is best to start again from scratch. concretingand removalofpipes from the pipeline.

Cleaning out
For short pipelines and boom-supportedpipelines much of the
concrete can be drawn back into the hopper by reversing the
pump. This makes cleaning easier. Alternatively pipes can be
disconnected and emptied of concreteindividually.Empty pipes
can then be washed with a hose.
Sometimes the air or water line can be conveniently
connectedto the discharge end of the pipe. The concrete can
then be discharged close to the pump where it can usually be
more easily removed. In addition, the cleaning plug can be

10
12
14

directed onto the ground near the pump and is less likely to be
lost.

Safety

Concrete in pipelines is often under considerable pressure.

Approved pipelines and couplings are designed to withstand
appropriate pump and line pressure. Appendix 3 of the BCPA

Figure 12: Pumping concreteon a ground slab,

working back from the furthestpoint towards the
pump.

AdvisoryCode gives details.

Never disconnect or change pipes while the pump is
operating. Whenever possible, reverse the pump to relieve
pressure in the pipeline.
Pipesfull of concreteare heavy. Whenshorteningor emptying
pipelines make sure that operativeswear protective boots or
shoes to protect their feet from injury.
If the end section of the pipeline is flexible it will move
violently when the cleaning plug passes through it. Keep
operativeswell clear.
Scaffolding must be designed to allow for vibrations and
additional loadings if pipelinesrest on it. Flexible pipesmust not
be allowed to kink, becausethismaycausehigh pressure to build
up which may in turn causeweak pipesorjointsto open or even
burst.

Figure 13: Two pumps pumpingconcrete into the base

ofa coffer dam.

Table4: Points to consider in planning and organization.

Obtaining equipment
Hire
Economical if sufficient
continuityof pouring
Sub-contractor
Singlepours
Regular basis
Cuts idle time
Selection of plant
Maximum outputrequired
Flexibilityand reach
Mix design (if marginal)
Mix design
Strength
Aggregates avaIlable
Agreement withclient
Minimum number of moves
Pump location
Access for concrete delivery
and turnround of lorries
Shortest average pipe runs
Minimum number of bends
Pipe layout
Use slow bends and straights
Keep pipes horizontal or vertical
Concrete supply
Site-mixed
Ready-mixed
Gang size
May be tess than for traditional
placingmethods
Formwork
Pour sizes and turnround will
dictate quantities required
Must resist pumping vibration

References
1.
2.

void content:new apparatus foraggregates, sandand

fillers. Garston, Building Research Establishment, current Paper CP19/69.
BRiTISH CONCRETEPUMPING ASsocIATION.AdvisoryCode for safetyin concrete
pumping.Second Edition. Fleet, 1982.
KEMPSTER,E. Measuring

Further reading
BRITISH CONCRETE PUMPING ASSOCIATION.

practice. Second Edition. Fleet, 1979.

The manual of pumped concrete

BLAcKLEDGE,GF. Man on the

job: Transporting concrete.Slough, Cementand

Concrete Association, 1975. Publication 45.107.

Acknowledgements
Theassistanceof the Plant AdvisoryService ofJohn Laing ConstructionLtd and of
the British Concrete Pumping Association in finalizing this digestis gratefully
acknowledged.

CI/SfB
q4

D3i

LDC 666.97.033.13
Concrete Society Digests are written by indinidoal aothors, onder the
editorial control of a Working Party of the Edocation, Training and
Publications Steering Groop.The editor forthisDigest was P. K. Donaldson.
Corrent members of the Working Party: R. Iatt IChairmanl, G. 1.
Blackledge, R. Blundell.I. N. Clarke (Secretaryl, E F. Homphries. F. V.
fenkins,S. H. Perry. Formermembers: S. R.ArnoldlChairmanl.l.D.Dewar,
P. K. Donaldson, D. M. Lambert.

j.

ISBN0721013066
tSSN0266-383X
Published by The Concrete Society
Devon House, 12-15 DartmouthStreet, LoodonSW1H 9BL
Designed and printed by the Cementand Concrete Association
Wesham Springs, Slough 5L3 6P1

Furthercopiesmay be obtainedfrom:
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quotingreference number53,045
Price GroupC52

0 The Concrete Society 1984

AlthoughThe Concrete Society Ilimitedbyguaranteel does itsbest to ensure
that any advice, recommendation or information it may give in this
publication orelsewhere isaccurate, no liabilityorresponsibility olany kind
lincludingliability for negligencel, howsoever and fromwhatsoever cause
arising, is accepted in this respect by the Society, itsservants or agents