Concrete pumping

Boom or line pumps can be used profitably on many smaller jobs

M assive base mat pours or high-rise projects may

include pump placements of thousands of cubic
yards of concrete. These record-setting projects some-
times obscure the fact that pumps are used on many
small- to medium-sized pours as well. Because of tech-
nological improvements in recent years, the pumps are
more reliable and line systems or placing booms can be
more quickly put into operation at the jobsite.
Contractors choose to hire a pumping service or to
buy their own pump for a number of reasons. On some
still save time and money. In narrow walls the pump dis-
charge hose can eliminate the need for drop chutes and
elephant trunks. And because concrete can be placed
closer to its final position in the form, less shoveling or
dragging is necessary to move the concrete. On pours for
foundations, slabs on ground, and multistory structural
frames as well, faster placement rates reduce the num-
ber of man-hours needed and cut down on overtime. La-
bor savings will frequently offset the costs of pumping
even on smaller pours.

PUMPS FOR THE BREAD-AND-BUTTER JOBS

Pumps mounted on trailers

Trailer-mounted pumps can be used on smaller jobs
to move concrete through placement lines with diame-
ters anywhere from 2 to 5 inches. The smallest pumps,
equipped with 2- or 212-inch placing hoses, are suitable
only for concretes made with pea gravel (38 -inch maxi-
mum size) aggregates. Users of these pumps should
know that considerably more water is needed to get a
desired slumpand more cement to get a desired
strengthwhen small-aggregate concretes are used.
The big advantage is that smaller hoses are easier to
move around. Ten feet of 212-inch hose filled with con-
crete weighs only about 50 pounds.

Small, trailer-mounted pumps are particularly useful on

repair or rework projects. For the job shown here, new
patios were being built in the courtyard of an existing
condominium. Only 8 to 12 cubic yards of concrete were
needed for each pour and pumping was the only feasible
way to place the concrete.

jobs access is a problem and pumping is the only way

that concrete can be placed. One pumper tells of break-
ing a hole in the sidewalk outside of a university build-
ing, and running line into the subbasement for a 30-cu-
bic-yard pour. On another occasion a contractor was
willing to pay the pumper a $400 minimum charge to
place only 12 cubic yard of concrete. There was no other
way to get the job done. Pumping is well-suited for plac-
ing concrete for mezzanines, balconies, free-standing
columns and many types of repair work inside existing
buildings. When the pour is accessible by crane but the
crane must be pulled from other work or doesnt have
the needed capacity for fast concrete placement, pump-
ing is often the most economical placing method. Reach of a truck-mounted boom was extended here by using
On jobs where access isnt a problem, pumping can additional lengths of steel line.
 Many of the smaller trailer-mounted pumps having
capacities from 20 cubic yards per hour and up can
pump concrete with up to 112-inch maximum size ag-
gregate if the line size is adequate. These pumps are
small enough to be towed by a pickup truck and a major
advantage is lower cost than for truck-mounted units
with booms. Prices for single-cylinder pumps of this
type start at about $20,000 while two-cylinder pumps
will cost anywhere from $30,000 to $45,000.
The amount of pressure a pump can generate is a ma-
jor factor in determining how far the pump can move
c o n c re t e. Maximum vertical pumping ability for the
smaller trailer-type models is typically between 100 and
300 feet while maximum horizontal distances that are
possible may range from 500 to over 1200 feet. The ver-
tical and horizontal limits cant be achieved simultane-
ously.
Smaller trailer pumps are used advantageously to
place concrete for patios, swimming pools, sidewalks
and similar projects in residential neighborhoods. In
rural areas, where travel time costs for a pumping service
could be prohibitive, applications have included raised
silo bases, manure holding tanks and floors for auction
rings. The pumps are also useful on projects where sev-
eral smaller pours are to be made on several different
days. On these jobs, the vertical pumpline can be tied
down and left in place, saving setup time.
One disadvantage of trailer pumps is the time re-
quired to set up the line system. Also, on muddy sites the
pump and pickup truck are more likely to get stuck than
is a larger, more powerful truck-mounted unit. And if
high production rates in cubic yards per hour are re-
quired, the smaller pumps may not have enough capac-
ity. One contractor uses his trailer pump for jobs under
50 cubic yards but goes with a bigger truck and boom for
jobs with more yardage.
Truck-mounted pumps with placing booms
Using a truck-mounted concrete pump with placing
boom, a pump operator can drive to the jobsite and be
ready to pump soon after he arri ve s. Very little breakout
and setup time is needed. He can boom up and out,
quickly delivering concrete to most hard-to-reach spots.
Nearly every major pump manufacturer makes lower
capacity truck-mounted pumps with placing booms
that are well suited for smaller pours. Many are mount-
ed on a two-axle truck which is less expensive and more
fuel efficient than tandem-axle models. New and used
units are available with piston or squeeze - p re s s u re
pumps having theoretical capacities starting at 25 cubic
yards per hour. The actual capacity or output in cubic
yards per hour for any pump will vary with how far the
concrete is being pumped and with mix characteristics
affecting pumpability. Pumps can be designed to deliv-
er either greater volume or greater distance.
Pumping booms have vertical reaches of 60 feet and
up and line diameters of 3, 4 or 5 inches. Some will rotate
through a 360 degree arc while others are limited to a
smaller slewing range. Articulating or telescoping de-
signs allow the boom to unfold and to place concrete
straight out, straight up or downward. Remote control of
the boom functions is a feature of many models.
The reach of boom pumps can be further extended by
attaching the boom to a pipeline system set up at the
jobsite. Pump capacity then determines maximum hor-
izontal and vertical distances that can be achieved.
SELECTING THE RIGHT PUMP
Concrete pump manufacturers usually list a maxi-
mum theoretical output or pump capacity in cubic yards
per hour for the models they manufacture. But for any
concrete pump, this maximum attainable output in cu-
bic yards per hour will decrease as line resistance in-
creases. Factors that increase line resistance include:
longer lengths of horizontal line
line that rises vertically
smaller line diameters
changes in line diameter (reducers)
bends, especially sharp bends, in the line
Slump and other concrete properties also affect line
resistance. Generally, more pumping pressure is needed
to push low-slump concretes through straight lines or
through bends and reducing sections.
The pump manufacturer or distributor can be con-
sulted for help in selecting appropriate equipment. The
contractor knows how much concrete he needs to place
per hour, but the pump will seldom be in operation for
60 minutes out of every hour. De l i ve ry output for the
pump must be approximated, based upon estimated
downtime. This output, plus the size pipe to be used, job
layout and concrete properties are taken into account
in calculating the required pumping pressure. Then the
combination of output and required pumping pressure
can be used to choose the best pump for the job.
GETTING MAXIMUM BENEFITS
FROM DOLLARS SPENT ON PUMPING
The basic requirements for a fast-moving, smooth-
running pump pour are a level site for the pump, with
room to get ready mix trucks in and out; timely delivery
of a pumpable concrete; and enough people on the plac-
ing and finishing crews to handle the concrete.
Spotting the pump
Boom pumps must be set up so that they are within a
few degrees of being level. That means you need not on-
ly a level site but also one where the surface is firm
enough to support the weight of the truck and the pres-
sure beneath the outriggers. A level surface isnt as criti-
cal for trailer pump operation. The trailer pump should
be positioned as close as possible to the forms or area to
be concreted last.
Ideally, there should be enough room at the pump to

Smaller pumps can be used effectively when thin concrete
overlays are placed because the rate at which concrete can
be finished will frequently dictate the pump capacity
needed.
have two concrete trucks at the hopper so pump time
isnt wasted while trucks are maneuvering. On slow-mov-
ing pours with a small capacity pump you may be able to
get by with room for only one truck, but you wont be
making the most efficient use of the equipment.
Check the location of overhead lines, too, when youre
spotting a boom pump. Powerlines are a safety hazard
and many pumpers wont operate a boom pump near
them.
Finally, measure the distance between where youre go-
ing to set up the pump and the farthest point you need to
reach. That will determine how much line is needed or
how long the boom has to be. When youre deciding what
length boom to order remember that the maximum hor-
izontal reach of a boom will be about 10 to 20 feet shorter
PUBLICATION #C850177
Copyright 1985, The Aberdeen Group
All rights reserved
than the stated length. If you order a 100 foot boom youll
be able to reach about 85 feet straight ahead of the front
bumper.
Ordering and scheduling the concrete
Tell the pump operator ahead of time what kind of con-
crete hell be pumping. The coarse aggregate maximum
size affects the line diameter required; 5-inch-line sys-
tems are needed for 1 1/2-inch aggregate and 4-inch-line
systems are usually adequate for 1-inch or smaller aggre-
gate. The operator will need to know whether hardrock or
lightweight concrete is to be pumped and hell probably
want to look at the mix design if its for a concrete mix that
he hasnt pumped previously. Slump, cement content, ad-
mixtures used, sand grading and type of coarse aggre-
gate used will all affect pumpability.
So that pump time isnt wasted, schedule concrete de-
livery to start about 15 minutes after the pump arrives on
the jobsite. Long delays on concrete delivery will sub-
stantially increase the cost of pumping and the bigger
the trailer pump or boom truck being used, the more
costly the delays will be.
Having enough workers on hand
To take full advantage of the faster placing rates for
pumped concrete, have enough workers on hand. Dis-
charge hoses on line systems and booms on truck-
mounted pumps are very maneuverable, so fewer people
may be needed to get the concrete in place. But on flat-
work jobs you might have to use more finishers. For slab
pours on metal decks or thin toppings for repair applica-
tions, the amount of concrete that can be pumped per
hour will depend mainly on how fast it can be finished.