Natural Pozzolans

Natural Pozzolans are an ancient form of cementious material and have been used for thousands of years. They have been occurring naturally since, well...practically forever, at least since there was life on earth. Called Pozzolan for the village of Pozzuoli where great volcanic eruption from Mount Vesuvius had deposited a large volume of volcanic ash in 79 AD. Pozzuoli, located near Naples, made the most of this misfortune and beginning mining this material which was an already proven material with cementious properties. Pozzolan was likely the first cementious material being used in the ancient world. Timelines show uses of such materials dating back to 3000 BC when both the Eqyptians and Chinese were incorporating them inmajor infrastructure projects and beyond. I have heard, but can not yet verify, that when the very first civilizations began taking shape, around 6500 BC, in the area of what is now Syria and Jordan, it is likely that they were crafting their buildings, which can still be found today, with mortars consisting of Natural Pozzolans.

 

Today Natural Pozzolans have a use in concrete that is very similar to that of fly-ash.

They can be used as a partial replacement for the cement often in the range of 15% to 35% (per PCA Concrete Manual). They can improve sulfate resistance an can help manage the reactivity to alkali-silica. The physical nature of  Pozzolans helps to reduce permeability.

Natural Pozzolans that you are likely to come across are usually processed materials. They are heat treated in a kiln and are then pulverised into a fine powder.  These Pozzolans include Calcined Clay, Calcined Shale, and Metakaolin

Natural Pozzolans are classified by ASTM C 618

I have worked with a few companies that were both developing and using Natural Pozzolans. They seemed to have a Pozz-itive effect.

For more information on Natural Pozzolans and other Cementious Materials, Look Here:
http://www.ce.memphis.edu/1101/notes/concrete/PCA_manual/

Fly ash in Concrete

Fly ash has become a big part of the precast concrete industry. It is a useful addition to the cementious portion of a concrete mix. Because of its unique molecular shape it makes stripping molds off of dry cast products smoother, aids in longer product lives in certain applications, and beacause it is a by product of burning coal utilizing it within concrete is a beneficial way to capture and store an otherwise harmful material. But what is fly ash?

As I mentioned fly ash is usually a by product of burning coal. However fly ash is technically any ash, typically from a furnace that is airborne. Fly ash is usually used to replace 15-25% of the cementious material in a concrete mix. There are several benefits to using fly ash. A key one is that fly ash has excellent resistance to acids and its use in a concrete mix helps the product to resist the premature degradation caused by exposure to excrement and other acidic organic materials that can be found in the soil.fly ash is also resistant to sulphate and salt.

The round shape of the fly ash molecule adds an elegant elasticity and smoothness to the concrete mix. This is a great asset when pumping concrete and when stripping dry cast products in their green state.

Unfortunately, or fortunately, based upon your view point, Fly ash has become very difficult to get due the combination of an increased demand by concrete producers and, more significantly, greater environmental restrictions on the production and consumption of American coal.

Understanding Mixer Output

One of the most confusing parts of buying (or selling) a concrete mixer is understanding what the output of concrete will be. this not only because different manufactures have different names for the same sized mixers, some metric others imperial. The same mixer will have different output capacities based on the mix design. it is also different whether it is weight or volume  of output that is being analyzed. Generally speaking the weight of the material that you put into the mixer will (almost) always be the same as the weight of concrete that comes. But volume is a different story.

When you have a pile of stone, a good portion of that pile is actually air. There are voids (air space)between the individual stones. Even grains of sand have air voids where they are not touch adjacent grains. in the process of mixing concrete the voids between grains of sand are fill with hydrated cement dust, and the voids in the rock are fill by the combination of sand cement and water. Therefore, if you have cubic foot of stone, and 25% of that volume is air voids, you can expect that you will see that volume of reduction in your finished concrete (as the sand will fill these open spaces). Additionally, there will be further reduction as the cement particles fill the voids left in the sand. Generally, this reduction is around 1/3 to 1/4, though much greater or lesser reductions are not uncommon.

Admixtures can also play a notable role in volume changes to concrete, I think. But a lot of stuff with Admix is beyond me, and I am in know way an expert in that regard.

Really, the important this about mix volume reduction comes down to, how big of a mixer do you need to fill this form, or this Tucker, or this bucket, or machine hopper, etc, etc, etc. with X amount of concrete of X type. the kicker is if you don't get this answer right you will be living with it for years.

Here is my recommendation for getting the right size concrete mixer for your plant... Plan on shrinkage and understand mixer volume capacities. Get the technical information on the mixers you are considering. Compare the volume of the mixers to be sure that you are getting a mixer that can produce the volume of concrete you need. If it is a pan or a planetary mixer make sure that you don't have to go far above the paddles on your mix, as that will not mix as well, and it can be hard to make a mix homogeneous from top to bottom. With Twin shaft and Horizontal shaft mixers the concrete is blended more easily at greater depths, but over filling can lead to a mess.

There is of course much more to evaluating mixers. This is but a small part, but I hope that you find it helpful.

Mixing UHPC: Ultra High Performance Concrete

I was introduced to UHPC, or Ductal as it is often called, nearly ten years ago when visiting a concrete pipe plant in Quebec. They had been running tests with it and when they showed it to me, what I saw was a very thin sheet of very dark concrete. I remember the piece seemed no more than a quarter inch thick. Imagine my amazement when the plant manager casually tossed this material down to the concrete floor, and though the piece banged it did not break. It didn't even crack. I was enamored with this material. How could such a thin piece of concrete withstand that. I was told it was a secret and quite expensive mix that was being developed by one of the big cement companies.

Later that same year a very gifted engineer I know from Italy, told me about a way to make a concrete pipe that would have the tensile strength for it to handle lower head pressures. This was notable because concrete pipe that can handle internal pressures is almost always made with a steel liner to compensate for concrete's lack of natural tensile strength. My friend explained to me that the secret was in the mix design. He said that the mix would be a fine one, with a high quantity of Silica. In all honesty I think he explained the entire mix to me, but I retained only the word Silica. I now know that what he was describing is the mix we today refer to as UHPC or Ultra High Performance Concrete.

Years went by as they always do and other things took my attention (mostly concrete paver equipment), until I was lucky enough to meet a group of people that are a driving force in the development of Ductal / UHPC in North America. They were looking for a concrete mixer that could mix UHPC effectively and a mixer that could be transported to and easily set-up at bridge construction sites. After several discussions about the concrete and the projects, I had a feeling that a Praschaak horizontal shaft mixer would be the right tool for the job. I also quickly realized, as they explained this product, that this concrete may be a magical stuff I had seen and heard of nearly a decade earlier.

Only a couple weeks after our initial conversations about the making of UHPC I met up with a few experts from the Field at the Mixer Systems factory in Pewaukee, Wisconsin to run tests, trying to determine which mixer type would best suit the production of UHPC. As I suspected it was the Praschaak, but not for the reasons I had thought.

It was the horizontal shafts and powerful motor of the Praschaak that had propelled it beyond other mixer types such as the Pan and the Planetary. With the shaft sitting horizontal the arms and paddles sheer through the concrete vertically. This moves the materials from the top to the bottom of the mix, and from the bottom to the top. The paddles are also aligned to creat a flow in the mixer that creates an additional mixing action on the horizontal plain.

UHPC is a very dry concrete to mix, essentially a zero slump. What little water is put in seems to disappear and one would that that I could have no effect. Even after the addition of plasticizer, the mix tumbles around like dirt. But, given a bit of patience, the mix magically transforms to a thick taffy-like substance. It seems mystical to watch this unlikely transformation. Even the seasoned experts gathered to watch it happen.

It was that taffy like nature of the Concrete that made the Praschaak such an ideal solution for mixing it. It could be that all mixers would do an equally good job making UHPC up until this point transformation, but once that point is reached the Shaft and paddle configuration of the Praschaak is the bee's knees. As the paddle traveled through the mix, the mix would resist the inertia, and what came of this was a kin to the pulling of taffy. Indeed the mixed UHPC seemed solid when squeezed in a gloved hand, but it would ooze right though my figures when I relaxed the grip, and the Praschaak mixing method took great advantage of this property of UHPC to produce high quality and high efficiency mixes.

Modifying the mixer to be run on a job site rather than in the factory took some design and planning but had been done by Mixer Systems before, if never quite in this same manner.

Since we initially ran those tests and built those first mixers for UHPC at bridge sites. Mixer Systems has made several for this purpose and we have even built mixers and plants for the making of UHPC in factory setting for the decorative and architectural concrete industries.

There is, of course, Much more to be said of UHPC and how to mix it. This is just a quick tale of my experience.

If you have any thoughts or questions feel welcome to contact me

Steve Nelson
262-893-8554

Mixer Types: Making Sense of all the Options

There are a lot of concrete mixers out there in the market today for precasters to choose from. In my experience I have work closely with at least six distinct type of concrete, in passing with few other, from so many companies that it is beyond count. I have worked for three different companies that manufacture concrete mixers and worked for two other that sold concrete mixers as a part of Turn-Key projects (yes, that is five different employers...I know). Since I started in the concrete equipment industry 20 years ago I have learned quite a bit about concrete mixer for a factory setting, and here is what (I think) I know:

Counter Current Mixers (Planetary Mixers):

This is the mixer that I mostly grew-up around Pedershaab (which was the first company I sold equipment for) often paired their plants with Skako and sometimes Haarup, both Danish companies making Planetary mixers. Masa and Wiggert both make planetary mixers, and are companies I sold equipment for. Mixer Systems here is the US, and my current employer, also produces a planetary mixer. I have more experience with these mixers than any other.

In a nutshell, the planetary has the design to be one of the fastest mixing mixers available. they are good and reliable mixers. in some applications they excel beyond the pan and horizontal shafts. Also, the ability to have multiple discharge door as on the pan, can be a huge advantage. However, which today's more complex mixes such as SCC and even a standard zero slump, the mixing speed advantage is reduced. As I grew up, I saw the planetary as a one-size-fits-all, be-all-end-all of mixers. Today I see the planetary as a very useful tool in a belt of very useful tools, it has it applications but there may be better options, depending on what needs to done.

Cyclone /R12 Mixer:

This is an exceptional mixer, especially for Face-Mix on pavers. When I was with Masa, who produces paver plants, they produced a version of this mixer, and I was amazed at its ability to use a single shaft with mixing tines, revolving at an exceptionally high speed to pulverize the materials. this was very important as face mix is often prone cement and color balls because of the fine materials used. This is what high-sheer really is. Price on a mixer of this sort is often the biggest issue, as they often run 2 -3 times the price of another style mixer in the same size.

Another drawback to this mixer is a single discharge door though that can be overcome with proper planning and supplementary equipment.

Horizontal Shaft Mixer (Paddle or Spiral Blade):

Slow and Steady Wins the Race! When I first started with Mixer Systems, I had a bias against this mixer. Now I think it is the best mixer ever made. OK… that may be a little much, but let me explain my enthusiasm on this.

At Mixer Systems we call this mixer the Praschaak. There are other producers with this same design concept including Besser and, I believe, Columbia. They are seen as old technology,  often eliciting jokes such as "This is how cavemen made concrete". Maybe it is true that the technology is old, Praschaak was making this mixer in the 1940's, I have seen many in my travels running daily that were produced in the 50's and 60's. So, yeah they are old. They are simple to. A single horizontal shaft with either paddles or blades mounted to it turning at a pedestrian revolution every 1.5 -2.5 seconds. The body I like a barrel on its side, and yet it's produces just about every kind of concrete on the market and does a good job of it time and again.

I have seen horizontal shat mixers used for producing concrete pavers on various block and paver machines, and making consistent concrete with consistent colors, 4-5 minute cycles. Indeed the US block industry developed using such mixers. However, the real magic of the horizontal shaft mixer is for the producers of SCC that pour with buckets, this mixer's door design allows for the least amount of drop from mixer to buckets and that saves on clean-up. Also, the difference in mixing times of the Horizontal shaft and mixers such as the planetary or twin shaft become far less noticeable, within seconds of each other, once a plasticizer and/or other admixes are properly mixed in. Good concrete takes time regardless of RPMs

Pan / Turbin Mixer:

The pan is an interesting mixer. It is unique among the other mixers listed here as it does not have an open body to mix in. Instead, the center of the mixers body is dedicated to the transmission while a trough is created between the inner and outer wall where the mixing takes place. I used to consider this mix a cheap alternative to the planetary, but that was an incorrect and unfair assumption on my part while there may be several applications in which the planetary is said to be superior, I have on numerous occasions seen pan mixers performing noticeably better. At Mixer Systems we produce Turbin/Pan mixers, as do companies such as Teka and Voeller.

I have seen pans running 90 second cycle time while feeding a concrete pump in a precast operation. I have spoken to Prestress producers running both Pan and Planetary Mixers side by side, who have told me that the Pan is far superior for zero slump concrete, and that the mixers run at nearly the same cycle. Indeed, Pan mixers have been a mainstay in the concrete pipe industry for years.

Pans often consume more wear parts than mixer such as the twin and horizontal shaft mixers. But they also offer additional versatility by allowing for multiple discharge doors

Ready Mix Truck:

I am not a ready mix expert. Though wonderful for delivering concrete far and wide to remote locations, It is my understanding that mixing in a ready-mix truck requires up to 15% more cement than a batch mixer to get the same product strength. If I am wrong on this please correct me.

Twin Shaft Mixers:

The twin shaft mixer is a truly fantastic mixer. It offers mixing times similar to the Planetary, durability similar to the horizontal shaft, and a very dynamic mixing action. It is usually is a pretty expensive mixer and if it is not…Beware! This mixer, unlike a horizontal shaft is designed to have the material being mixed over the height of the shaft. This means that the shaft seals are in constant contact with concrete. Not such a big deal for dry cast concrete, but a very big deal with wet-cast, and especially SCC. Those running concretes are as crafty as water when it comes to finding ways to escape, and standard shaft seals would last forever (and by forever I mean 6 months) for such a mix, an air-purge or similar seal is critical, and they are not free.

Another small and easily overcome drawback to the twin shaft is that there is a single discharge door and it is the length of the mixer usually. A chute is often need to focus the flow of material.

 In Summary:
Each mixer type has its own unique assets and limitations there is no one mixer that is best at all things, though many do all things well. The biggest factors in choosing a mixer often relate to the plant designed around and the company you are working with.

Concrete Pipe Weights

I came across this nifty tool that I picked up at a Tri-State Concrete Pipe Association meeting. Great group, and a great tool. It holds more information than I can easily share, but for those of you, that are like me and spend their time wonder how much concrete by weight is in a 66" elliptical pipe... Ta - Da!

Sorry the quality sucks I will try find a better "weigh" to save it. Nice pun, aye?
Note: I updated the image, but kept the pun.

Making Concrete Pipe

There are a lot of ways to make a concrete pipe. In 1905 My great, great, great uncle John L. Ziedler came up with a pretty ingenious way to make pipe. it was a machine called a Packerhead, Europeans sometimes call this a radial-press. This method, which was developed almost simultaneously by McCracken (now Besser) was a significant step forward  in the production of concrete pipe in North America. This ability to mass produce quality concrete pipe help tremendously in the process of separating storm and sewer lines to create a cleaner healthier environment. it also gave access to the tools which would allow us to create the highway systems.

Today, however, a lot of pipe is made (in North America) with vibration, which is also a great method. I spent much of the beginning of my time with concrete equipment working with vibratory pipe production equipment. However, there are other methods for pipe production as well such as spinning and wetcast. What follows is a brief synopsis of these methods and my musings on the strengths and weakness' that I believe they offer.


Vibration:
The other methods are all very good, but if I were to choose one machine to run a pipe operation it would be a vibration machine. Most production methods incorporate vibration (with the exception of spinning) There are many vibration methods to choose from. The magic of vibration is that you can cast which ever shape of pipe the market demands. Round, Arched, elliptical, and even Box shapes can be accomplished with vibration. Below are descriptions of various vibration methods


Rising Core:
Only three machines I know of fit this description. The Pedershaab (now HawkeyePedershaab) Mastermatic series of machines and Hydrotile's (now Besser) Neptune which have now, all but vanished. There is one other which was called the Hydropac (also by Hydrotile). Only the Mastermatic is common today. The Mastermatic is a high output machine, that when pushed to its limit can produce in the area of 1000 8' joints per day, of pipe up to 24". Like the Packerhead machine it is generally limited to round pipe, unless it is equipped with header rings.

The Mastermatic has a vibrator mounted in the core of the mold, down about 2-3' from the top. this vibrator is mounted so that it distributes energy equally on all sides. at the top of the core the is a distributor (roller compactor) that pushes the low slump concrete that is being fed into the outer mold, and on top of the core, out to the edges and down. this material is then vibrated to get all of the entrapped air to rise up from the concrete as it is being compressed between the vibrating core and
the jacket of the mold.

This is a great machine for the fast production of reinforced concrete pipe as the concrete drops to the height of the core before being forced to the wall. This system is fast and makes excellent pipe, but it is a high maintenance system. It takes dedication and good operators to consistently run well.


Stationary Core:
In this method the core and the jacket of mold that forms the concrete pipe stand at roughly the same height and the concrete. This means that the concrete, usually a very low slump must fall a distance of 8' to go from the top of the mold to the bottom. With reinforcement this can be a slow process when compared to the Mastermatic or the Packerhead. it can also lead to excess air joining the concrete that will have to vibrated out to get a dense product. Despite these limitations these systems represent, what I consider to be, the best overall pipe production method.

When run with electric vibration mold can be quickly changed on a machine, so that a company can produce multiple shapes and sizes of pipe in a single shift. A few are even equipped with turn tables, which hold three molds, so that the filling process can happen at a natural rate while other processes such as vibration and demolding happen separately. Additionally with Electric vibration molds can be run with multiple cavities for making more than one pipe at a time.

This is an excellent method and if a company can have but one pipe machine to produce a full range for the North American market this is the one I would pick.


Jacket Vibration:
I am not a big fan of jacket vibration as it is very difficult to get and even vibration and will often leave spots that compact prematurely and create barriers that unwanted air cannot escape through. There may be advancements in jacket vibration, however,  that I am not aware of, and I have head lot of positive talk about Egg laying box culvert systems which use this vibration method. I think that jacket vibration is the necessary evil of having a system that can cast a large product and leave the product behind, rather than it being a superior vibration method. Feel welcome to rebute me on this as I am not an expert on jacket vibration, and I would like to give correct information.


Table Vibration:
Vibration tables are a reasonable method for producing large diameter pipe in all shapes. I have seen vibration tables making high quality pipe down to 24" in gang-forms (a form with cavities for more than one pipe. The important thing to remember with table vibration is that the vibration need to use the compacted concrete as a conduit to transmit it energy, so a small diameter pipe like a 12" provide a very narrow path, especially at heights of 8'.

Larger pipe 24"+ whether round, elliptical, or arched and box culvert are wonderful products for a vibration table. for a smaller producer or market where versatility is key, a vibration table and a packer combined could be a magic combination.

Vibration tables need to be made the right way for producing a concrete pipe. A vibrator can not just be strapped to a table with rubber dampeners. Making pipe on a table requires the ability to adjust both amplitude and frequency during the process of filling the pipe. The reason for this, as I see it, is that some of the energy of the vibration will be absorbed by the already compacted concrete, and this absorption or dampening effect will increase as the concrete height increase. However, if the lower levels of concrete are tightly compacted (with proper frequency and amplitude of vibration) this dampening effect maybe virtually erased.


Packerhead / Radial Press:
This system is near and dear to my heart, due to the family connection. The packerhead method of compacting concrete is about force. Not entirely about force, but mainly. The body of a packerhead pipe is made by compressing relatively low slump concrete between a steel outer form (jacket) and an interior roller head. This rollerhead is made to rotate by a shaft/shafts which connect the rollerhead to a driving motor. The roller heads distribute and compact the concrete as it is being fed into the mold working up from the pallet to the very top of the pipe. Below the rollerheads are a row of trowels whish smooth the compacted concrete

It used to be that the rollerhead could go only a single direction as there was only a single shaft running a single level of rollers. Today packerheads usually used stacked rollers that rotate in opposite directions as they are being run by two separate shafts.

Below the rollerhead is a vibration unit called the bellpacker. the pallet (usually a ring for forming the female connection) sit on the bellpacker, which vibrates, and helps compact the concrete. this has traditionally been a weak point for packerhead pipe as it is hard to get a tight compaction of concrete when the pallet jumps on the bell packer. I remember working on methods to secure the pallet to the bell packer to assure a tight compaction of the bell. This should be considered when looking at a packerhead.

Packerheads have the ability to make the highest quality concrete pipe with extremely low absorption rates, but they must be well run to accomplish this. They also can produce large quantities of a given pipe size as fast as any machine, but the are limited to round products and only a single size at a time.

There have been some notable improvements made to packerhead machines over the last 10-15 years. I would suggest that anyone who has a need to produce round pipe in high quanities look into packerhead production. Remember, however, that packerhead are good for round pipe only, and it would likely benefit any modern producer to be able to produce other shapes. My belief is that a packer head is a great machine to have in conjunction with another machine that offer the needed versatility.


Spun Pipe:
This method of producing concrete pipe is rarely used in the US for the production of RCP (reinforced concrete pipe). It is however used for pressure pipe manufacturing, especially by companies that are producing joints of 25'-50', where the concrete is being cast into a steel cylinder. Watching the spun pipe method is really amazing, as you see concrete defy gravity. This is because of the centrifugal force created by the rapidly spinning steel cylinder that the concrete is being fed into. the speed is so great that the concrete adheres to the wall of the cylinder and spreads evenly. furthermore, as the concrete materials shuffle to find the lowest possible point of order along the inner wall of the steel cylinder, the air and excess water is pushed out and away for the steel surface and what is left behind in a smooth dense interior finish.

I have heard that the pipe molds can on rare occasion come loose of the spinning systems. this sounds pretty terrifying to me.


Wetcast Pipe:
Producing concrete pipe with wet-cast was seen as old technology for a long time. Now, however, with improved automation and concrete production methods, wet-cast pipe production is again gaining popularity. SCC (self compacting concrete) is a big driver of this increased use of wet-cast. In other forms of pipe production it is hard to completely eliminate bug-holes (small voids) especially if you have a bell on the product. Air pockets under vibration can move fairly well (relatively) up a vertical surface of a mold, but often bog down when traveling a slope. SCC moves air far better than previous concrete, and when given even slight vibration the air quickly moves to the surface, leaving behind a very dense product with low absorption.

Companies have developed many new and improved ways to make and delivered high slump concrete to the molds. and quality benefits can outweigh the need to leave products in a mold to cure. There are a few North American pipe producers using wet-cast, but as the success of this method is more broadly realized, I expect that we will see it becoming a standard production method with large diameter pipe.

Final Note:
I do not work for or with any pipe machinery manufacturers. I worked with concrete pipe machinery for several years and enjoyed it immensely. I worked with Pedershaab, HawkeyePedershaab, and Teksam equipment, all of which made good quality pipe manufacturing equipment. I believe that most machinery producers selling in North America today are offering high quality equipment. My goal is to offer insight from a relatively neutral view in order to help current and future pipe producers know what methods are commonly available.

One More Thing:
If you need a mixing and batching solution to help with you pipe production... I do sell those, Mixer Systems. Please feel welcome to contact me to learn more about the process of making concrete.  262-893-8554  I look forward to hearing from you.