1. Concrete Industry Board Morning Seminar – 10/13/2011 Concrete Pumping: Rocket Science meets Common Construction James Bury Director – Engineering Putzmeister America

2. Concrete Pumping & Placement

3. World Records in Concrete Pumping Burj Khalifa tower (Dubai) – 606m vertical Le Refrain in Haut Doubs, France 2km horizontal

4. Sensational Achievements Panama Canal Expansion Hoover Dam BypassTrump Tower - Chicago

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6. Concrete Pumping Dependency Cement proportion Water proportion Fly ash type Fly ash proportion Silica fume type Silica fume proportion Slag type Slag proportion Water reducer usage Viscosity modifier usage Accelerator usage Aggregate gradation Aggregate roughness Aggregate porosity Aggregate moisture Aggregate max. size Aggregate shape Sand fineness modulus Sand roughness Sand moisture Sand proportion Cement type Decelerator usage Total mortar content Total fines content Fiber type & size Fiber content Age of concrete Batching quality control Material storage QC Temperature Component suspension On-site water addition Mix and Environmental Factors

7. Concrete Pumping Dependency Available engine power System power losses Hydraulic pressure capability Condition of wear items Hopper configuration Hopper agitator effectiveness Vibrator location Delivery cylinder size & length Delivery cylinder inside surface Delivery path continuity Boom arm configuration Heat added by equipment Volume output Vertical pumping distance Horizontal pumping distance Number of elbows Elbow radius and angle Number of reducers Length & diameter of pipeline Pipeline pressure rating Water-tight pipeline (no leaks) Dent free pipeline Steel pipe vs. rubber hose Equipment & Application Limiting Factors

8. Concrete Pumping - Estimation Job Specific: Volume Output Pipe Diameter Horizontal Length Vertical Length Slump Equipment Specific: Engine Power Line Pressure

9. Concrete (Artificial Rock) Aggregates Smaller Grains < 2mm (sand) Cementitious Materials (cement, fly ash, silica fume, slag) Water Admixtures (water reducers, accelerators, decelerators, viscosity modifiers, colorants O

10. Aggregates / Sand Maximum Size (1/3 Rule) Gradation Absorption/Porosity Shape & Smoothness Abrasiveness

11. Water/Cementitious/Admixtures Cementitious Materials Cement Fly ash Silica fume Slag Water Admixtures Water reducers Accelerators Decelerators Viscosity modifiers Colorants

12. Concrete Pumping Hopper Reservoir Isolator Flow Assistance/Manager Delivery Cylinders Pull From Hopper Begin Pumping Cross-Section Push Into Valve & System Distribution Valve Cylinder-to-Delivery Lines Refinement of Cross-Section

13. Concrete Pumping - Delivery Mix Distribution Center  Aggregate Rich  Freedom of Movement  Shear Flow Boundary Layer  Aggregate Free – Mortar Rich  Friction avoidance Disruptions to Flow Elbows Gaps, Dents, Edges Reducers

14. Concrete Pumping - Delivery Disruptions to Flow Elbows Gaps, Dents, Edges Reducers

15. Mortar & Fine Matter Content Mortar Content Ratio (Mix ingredients < 2mm size) Suspension and Transport Media Minimum 50% by volume Fine Matter Content (Mix ingredients < 0.125mm size) Friction Fighter Minimum 400 lbs/yd³ Water/Cementitious Ratio (Traditional Indicator) Flow enabler Cement: Minimum 0.40 (40% water) Cementitious: Depends on mix

16. Example Mix Design & Analysis Material Weight (lbs)Lbs/ft³ Volume (ft³) Cement3841971.95 Fly Ash501440.35 #2 Natural Sand107510010.75 #57 Limestone11001626.79 #4 Limestone6001623.70 Water200623.23 Air1.0%00.27 3409Total27 CriteriaActualReq'dStatus W/C (by weight)4640% - 60%OK Mortar volume (ft³)16.5>13.5 ft³OK Fines (by weight)434 >400 lbs/yd³ OK The Good

17. Example Mix Design & Analysis Material Weight (lb)lbs/ft³ Volume (yd³) cement2651971.35 fly ash1151440.80 slag3251811.80 silica fume201440.14 sand14301628.83 aggregate - #5711701726.80 aggregate - #85001722.91 water225623.61 air3.0%00.81 4050Total27.0 CriteriaActualReq'dStatus W/C (by weight)0.31.40 -.60Very Low Mortar volume (ft³)17.3>12.1 ft³OK Fines (lbs)725 >400 lbs/yd³ OK but high The Bad

18. Example Mix Design & Analysis The Unpumpable Material Weight (lb)lbs/ft³Volume (yd³) cement6851973.48 fly ash3001751.71 silica fume301440.21 sand13751628.49 aggregate - #5710801756.17 aggregate - #84501752.57 water250624.01 air1.5%00.41 4170Total27.0 CriteriaActualReq'dStatus W/C (by weight)0.25.40 -.60Extremely low Mortar volume (ft³)18.3>12.1 ft³OK Fines (lbs)1015 >400 lbs/yd³ Very High

19. Mix Consistency

20. In Process ACI 304.2R – Placing Concrete by Pumping Methods Overhaul of 1996 standard Publication 2012? ACI 211-P – Proportioning for Pumpable Concrete New standard Draft stage Publication 2013? ACI 238 – Workability of Fresh Concrete Rheology as method of predicting workability/pumpability Effective & cost efficient method of replacing slump cone

21. Thank You