PRODUCTION OF CONCRETE

Production of concrete involves :

• 1) Batching
• 2) Mixing
• 3) transportation
• 4) Placing
• 5) Compaction
• 6) finishing
• 7) Curing
Batching of material
• Measurement of material for making concrete accurately.
• Two methods ; 1) Volume batching & 2) Weigh batching
• 1) Volume batching : not good method of proportioning.
• All operations are done manually.
• Done only In less important work.
• Gauge boxes or formas can be used .
2) Weigh batching : correct method.
- Is accurate, flexible and simple method.
- Batching equipment can be : manual, semi-automatic
and automatic batching
• Semi automatic : aggregates bins are used to
discharge from gates which are manually operated
by switches which allow the opening of gates.
• Mobile plant are also there where batching
equipment are mounted on pneumatic tyred wheels
which keeps it closer to site.
• Used in large area like roadways, runways
• Corrections in fields are done automatically in
automatic batching
2) Mixing of materials
• The object of mixing is to coat the surface of aggregate with the cement paste and blend all
the ingredient into a uniform mass.
• In mixing 2 actions are involved : i) blending of aggregate ii) application of cement paste.
Mixing

Hand Mixing Machine Mixing

• Hand Mixing : done by hands,
• Unimportant works
• Not efficient method
• 10% more cement needs to be added
• Aggregates are spread first in layers, then cement is spread over it, dry
mixing is done and then water is added.
Machine mixing
• Done for R.C.C work for medium scale / large scale
• m/c can be 1) tilting type 2) non tilting type 3) pan / stirring mixer.
• Mixing in machine can be in : a) batch mixing : concrete is produced
in batches. B) continuous mixing : continuous production of concrete is
required.
• Tilting type machine : bowl shaped drum
• Vertical vanes connect concrete
• Discharge action is by tipping of material through
gravity.
Buttering action is required so that material does not
Stick on the sides of drum
• 2) Non tilting type : cylindrical in shape
• Material is fed from top
• Slow rate of discharge so possibility of segregation
• 3) Pan Mixer type : circular pan rotating about
own axis.
Used in lab.
Effective for stiff and cohesive type of mix

• 4) Mini batching plant :

3) TRANSPORTATION
• Concrete has to be transported to point where it has to be placed without
segregation of material and setting
• Requirements are : a) no segregation of material and 2) proper consistency
of the mix
• Methods of transportation
1. Mortar Pan
2. Barrow method
3. Crane, bucket and ropeway
4. Tippers and lorries
5. Truck mixers and agitators lorries
6. Mono rail system
7. Pumps and pipelines
Transporting concrete
4) Placing of concrete
• Placing of concrete is to place it at proper place without segregation,
Bleeding and with uniform consistency and homogeneity.
• Examination of formwork for line, level and toughness
• Cleaning of reinforcement and formwork
• Size, spacing and location of reinforcement should be checked. It
should be properly spliced, anchored and embedded to a given
minimum distance.
• Fixtures should be properly placed in position
• Care should be taken that concrete is not dropped from heights as it
will lead to segregation of material.
• When fresh concrete is to be placed on previously placed and
hardened concrete, then all the foreign particles and laitance is to be
removed. Receiving surface should be made rough. Rich mortar
should be poured first.
• Sand blasting can also be adopted in case of dams
• In case of large work, the surface is left rough.
• In case of beams & columns, tightness of form work is to be ensured.
Greasing agent is to be applied inside. The reinforcement should be
free from oil and grease. Segregation should be avoided in heavily
reinforced section and for this either chute method or tremie method
of placement should be adopted.
• Placing under special conditions:
a. Within the earth mould ( foundation concrete for wall / column)
b. Large earth mould or timber plant formwork ( road slab, airfield
slab)
c. In layers within timber or steel shutters
d. Within usual formwork
e. Under water
* when placing within earth Mould : all the loose material should be
removed.
• Surface should be damped and leakage any should be blocked
• In case of footing and thin wall sections, it should be placed in layers
not less than 150 mm in depth.
• Concreting should start from the end and should continue towards the
centre.
• On slope it should begin from lower end of the slope.
• In case of columns and walls, it should be allowed to stand for 2 to 3
hours before pouring of concrete for slabs/ beams
• In case of cast in situ piles since conc. Has to be dropped from a height
, placing operations should be continuous in nature.
• In case of mass concrete work, concrete should be placed in layers.
Several layers may be placed in succession to form one lift but cold
joints should be avoided. The thickness should be such that vibration
is possible.
• In case of dams, surface preparation is done by high velocity air
jetting and water as soon as concrete is hard enough – all aggregate
and laitance is removed and then new concrete is placed.
• The surface can be cut upto a depth of 3 mm and surface may be
protected form climatic change effect by covering with moist sand
which can be removed and concreting can be done.
• In case of highway and runway, slip form of paving and fixed form of
paving is used.
• Slip form is generally used for tall buildings. In this method the
concrete is continuously placed, compacted and formwork is pulled by
no. of hydraulic jacks. The rate of slipping depends upon the strength
development and temperature of concrete.
• In case of road slip form is used where finishing operation, &
spreading is carried out simultaneously.
Stripping time
• Form work should not be removed until concrete has developed suff.
Strength of at least twice the stress to which it may be subjected at
the time of removal of formwork.
• Guidelines given in IS 456 should be used.
Stripping of formwork
Under water concreting
• Bottom dump bucket or tremie pipe is used for under water
concreting.
• In bottom dump bucket concrete is taken through the water in a water
tight box or bucket and bottom is open and whole concrete is dumped
slowly at required place.
• Some washing of cement paste may take place
• A ‘ tremie’ pipe can be used. It is a 20 cm dia. Pipe with easy coupling
for increase or decrease of length. A funnel is attached at the top for
concreting pouring while at the bottom plug /polyethylene is attached
to prevent the water seepage.
• Whole length of pipe is filled up and slight jerk is given by winch and
pulley arrangement. Fall of concrete takes place due to its weight.
• Top layer is scrubbed and removed.
• No entry of water takes place.
Compaction of concrete
• The process of removal of entrapped air and a uniform placement of
concrete to form a homogenous dense mass is called compaction.
• It is achieved by doing external work on concrete.
• Air is not completely removed, results into loss of
strength
• 5 % of voids strength is decreased by 30%
• 10% voids strength reduces by 50%
• Compaction increases durability and resistance
to chemical attack
Compaction methods
1. Hand compaction : rodding, ramming and tamping
2. Compaction by vibration
1. Internal vibrator
2. External vibrator
3. Table vibrator
4. Platform vibrator
5. Surface vibrator
6. Vibratory roller
3. Compaction by pressure and jolting
4. Compaction by spinning
Hand compaction
• Generally done in small works
• Also done in case where reinforcement is large and compaction by
other means is not possible.
• Thickness – 15 to 20 cm
• Rodding consists of 16 cm dia. Rod with 2 m length. Compaction done
over entire area
• Ramming done generally in ground floor construction or in
foundation. Not used in reinf. Conc. As it disturbs placing of reinf.
• Tamping: done for roof/floor slab or road pavement where thickness
is less. Consists of beating top surface by wooden cross beam of 10 x
10 cm.
Compaction by vibration
• Used for high strength concrete.
• Stiff conc., with low w/c ratio.
• Mechanical equipment used.
• Vibrators sets fresh concrete particles in motion, reduces friction
between them and does easy settlement.
• Due to vibrator less water is used. Therefore, low slump con. Is
preferred but strength and impermeability is high
• A) internal vibrator:
• Most commonly used.
• Also called needle, immersion or poker vibrator
• Consists of power unit, flexible shaft and needle.
• Needle length 25 to 90 cm
• Bigger needle for mass concrete work
•2) Form work ( external vibrator)
•Used for concreting columns, thin walls and pre-cast units.
•Machine is clamped on external surface of formwork
•Should be use where reinf. Hinderence is there
•Consumes more power and has low efficiency as it is indirectly
applied.
3) Table vibrator: used in labs/ prefabricated R.C.C units of small size
4) Platform vibrator : used in large prefabricated work like railway
sleeper, roofing elements, electric poles.
Consists of large table
5) Surface vibrator : also called screed board vibrator. Small vibrator is
placed on the screed board. Used on floor slabs, roof slabs and road
surface. Not efficient for more than 15 cm thickness.
Compaction by pressure and jolting
• Used for very dry concrete.
• Stiff concrete is vibrated, pressed and given jolts.
• Due to combined action of jolts and pressure compaction takes place.
• Used generally for compaction of hollow blocks, cavity blocks and
solid concrete blocks.
Compaction by spinning
• Used for prefabricated pipes.
• The plastic concrete is spun at high speeds, gets compacted due to
centrifugal forces.
• Commercially available as hume pipes, spun pipes.
Roller compacted concrete
• Also known as vibratory roller compacted.
• Used in dams and pavements
• Base course
Re Vibration
• It is the delayed vibration of concrete that has been placed and
compacted.
• When done in plastic stage generally lesser than 1 hour results in high
strength due to re arrangement of particles , diminishing of
entrapped air and achievement of full compaction.
• Plastic shrinkage cracks can be closed.
Curing of concrete
• When cement comes in contact with water, hydration process starts
both outwards and inwards. Hydration products get deposited at the
outer periphery of cement grains, and the nucleus of the unhydrated
cement gets gradually diminished in volume.
• At any stage there is gel, unreacted cement particle, Ca(OH) 2, water
• Development of strength starts immediately after setting and
continues indefinitely.
• The hydration of cement takes place when capillary of pores are
saturated. The additional outside water will fill gel pores.
• Process of creation of compaction of the environment, during a
relatively short period immediately after placing and compaction of
the concrete, favourable to the setting and hardening of concrete is
called curing.
• Curing increases compressive strength, improves durability,
impermeability and abrasion resistance.
• Favourable conditions for good strength are:
• A) adequate moisture within the concrete to ensure sufficient water
for continuing hydration process.
• B) warm temp to help chemical reaction.
Water Curing
• It is pointed out that even if the membrane method is adopted it is
desirable that a certain extent of water curing is done before the
concrete is covered with membrane
Membrane Curing
• Sometimes concrete work is carried out at
a place where there is shortage of water.
• Therefore lavish application of water in
curing is not possible it has been pointed
out that curing does not means
application of water ,it also means to
create uninterrupted and progressive
hydration
• Large number of sealing compounds and
agents are used as membrane so that
water does not evaporate from concrete
Heat Application
• Steam curing
The development of strength of concrete is a function of not only time
but also temperature.
When concrete is subjected to highest temperature it accelerates the
hydration process resulting in faster development of strength .
concrete cannot be subjected to dry heat to accelerate the hydration
process as presence of moisture is also essential in concrete .
TYPES OF HEATING CURING

• Steam curing at ordinary pressure

• Steam curing at high pressure
• Curing by infra-red radiation
• Electrical curing
Finishing
• Surface finish : 1) form work finish
• 2) Surface treatment
• 3) Applied finish
.