HEIGHT LIMITS ON CONCRETE FREE FALL

Q: -

We're placing concrete for a job with 10-foot-high columns, 18x18 inches in cross section.
The columns contain four #8 vertical bars. The fastest way to place the column concrete is by
direct discharge because there's an unobstructed path to the bottom of the column. After we'd
placed several columns this way, the Engineer said we had to use a tremie hose because
concrete shouldn't free fall more than 3 to 5 feet. ACI 301 is the specification for this job and
I can't find any mention in the specification of a height limit for concrete free fall. We've
already stripped columns and there's no evidence of segregation or honeycombing. Is it
necessary to use a tremie under these conditions? And if so, what's the maximum permitted
height for dropping concrete without a tremie?

A: -

Some publications used to give a recommended free fall for concrete. However, ACI 301
makes no mention of a 3- to 5-foot limit.

ACI's Guide for Measuring, Mixing, Transporting, and Placing Concrete (ACI 304R-89) in
Section 5.4.1 gives some precautions for placing. The guide says equipment should be
arranged so that the concrete has an unrestricted vertical drop to the point of the placement.
The stream of the concrete shouldn't be separated by permitting it to fall freely over rods,
spacers, reinforcement, or other embedded materials. If forms are sufficiently open and clear
so that the concrete isn't disturbed in a vertical fall into place, direct discharge without the use
of hoppers, trunks, or chutes is usually desirable.

PCA's Design and Control of Concrete Mixtures (13th edition, page 104) specifically
addresses your question. This source says the height of free fall of concrete need not be
limited unless a separation of coarse particles occurs (resulting in honeycomb). If honeycomb
does occur, a limit of 3 to 4 feet may be adequate. The PCA book cites a study in which
concrete was dropped vertically 50 feet into a caisson. There was no significant difference in
aggregate gradation between control samples as delivered and free-fall samples taken from
the bottom of the caisson. This showed there was no segregation.

Source: https://www.concreteconstruction.net/how-to/height-limits-on-concrete-free-fall_o

(A) CONCRETE PLACEMENT RATE

The speed or flow rate at which concrete is placed has many variables that must be
considered prior to placement. For example:

• Linear Length
• Height of Wall
• Temperature

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• Concrete Mix
• Placement Method
• Available Manpower
• Overall Time from Start to Finish.

Pre-planning is essential for a successful placement.

(B) CONCRETE PLACEMENT LIFT HEIGHTS

Concrete placement is recommended in 4 feet lift heights. This does not mean that the
concrete cannot be placed greater than 4 feet in height. The concrete is typically placed in a
continuous operation in multiple lifts - two, three or four lifts, by making continuous passes
around the perimeter or section of the wall to achieve the full height required. In typical
residential construction, concrete is commonly placed in a wall to a maximum of 10 to 12
feet in height during one concrete pour. This is done in multiple lifts of around 4 feet or less.
In commercial construction walls may be higher -14 to 18 feet. These walls also have the
concrete placement in multiple lifts following the same procedure.

(C) CONCRETE FALL HEIGHTS

A structural engineer, a specifier, or an inspector may want to limit the maximum free fall
height of concrete placement with the intent to prevent segregation. The American Concrete
Institute (ACI) does not directly address the height of concrete placement. Neither ACI 301,
“Specifications for Structural Concrete,” nor ACI 318 “Building Code Requirements for
Structural Concrete,” limits the maximum distance concrete can free fall. Field studies have
shown that free fall from great distances does not reduce concrete quality or compressive
strength. In the specification notes to owner’s representative, ACI 336 states that recent
research on free-fall concrete has confirmed that free fall does not cause segregation, at least
for fall heights up to 60 feet. The American Society of Concrete Contractors (ASCC) has
written a Position Statement #17 addressing the free fall of concrete. At least four field
studies have shown that free fall from great distances does not reduce concrete quality. The
ASCC position statement goes on to state that although the field studies have been for
caissons, the results should also apply to other structural elements such as walls, columns,
and mat foundations. ASCC references a 1994 FHWA study the provided test data leading
the investigators to conclude that “the general expectation that concrete striking of the rebar
cage will cause segregation or weakened concrete is invalid and they found “no segregation
or strength differences between low and high slump concrete mixtures.”

Source: https://dogk5k0c5kg4s.cloudfront.net/web/legacy/uploads/2017/10/1.06.02-Concrete-Placement-Lift-Fall-Heights.pdf

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