Why is it crucial to minimize the free fall height of concrete during placement?

Minimizing the free fall height of concrete during placement is crucial to prevent segregation. Segregation is the separation of the different components of concrete, namely coarse aggregate, fine aggregate, cement paste, and water. When concrete falls from a significant height, the larger, heavier aggregate particles tend to separate from the lighter cement paste and water due to differences in their mass and momentum. This segregation results in a non-uniform distribution of materials within the concrete, leading to variations in strength, durability, and surface finish. For example, if coarse aggregate segregates to the bottom of a form, the upper layers will be deficient in coarse aggregate and may have a higher water-cement ratio, resulting in a weaker and less durable surface. Similarly, if cement paste segregates, it can lead to excessive laitance, a weak, milky layer on the surface. Minimizing the free fall height, typically limited to around 1 to 1.5 meters (3 to 5 feet), reduces the impact force and the tendency for the different components to separate. Using tremies (pipes or chutes) or pumps to deliver concrete to the placement location also helps to control the flow and minimize free fall, ensuring a more homogenous and consistent concrete structure.