Mixing of Concrete

Concrete is mixed by two methods, based on requirement as per quality and quantity of concrete required.
Normally for mass concrete, where good quality of concrete is required, mechanical mixer is used. The
main purpose of mixing the concrete is to finally obtain a uniform mixture that shows uniformity in terms
of color and consistency.

Hand mixing of Concrete

Carrying out hand mixing of concrete requires special skills and care during the process for quality
control of fresh concrete. The precautions and the correct way of performing hand mixing of concrete is
to undergo the mixing process as recommended by the standard procedures. Mixing by hand is employed
only to specific cases where quality control is not of much importance and quantity of concrete required is
less. Stone aggregate is washed with water to remove dirt, dust or any other foreign material before
mixing.

Hand mixing should be done on a smooth, clean and water tight platform of suitable size in
the following manner:

1. Measured quantity of sand is spread evenly.

2. The required quantity of cement is dumped on the sand and spread evenly.
3. The sand and cement is then mixed intimately with spade, turning the mixture over and over
again until it is of even color throughout and free from streaks.
4. The sand cement mixture is then spread out and measured quantity of coarse aggregate is spread
on its top. Alternatively, the measured quantity of coarse aggregate is spread out and the sand
cement mixture is then spread on its top.
5. The whole mass should be mixed at least three times by shoveling and turning over by twist from
center to side, then back to the center and again to the sides.
6. A hollow is made in the middle of the mixed pile.
7. Three quarters of the total quantity of water required should be added while the materials are
turned in towards the center with spades. The remaining water is added by a water-can fitted with
rose head, slowly turning the whole mixture over and over again until a uniform color and
consistency is obtained throughout the pile.
8. 5 percent extra cement shall be added than the specified for machine mixing, when hand mix
cement concrete is produced.
9. The required PPEs (Personal Protective Equipment) shall be worn by the labors and masons while
mixing and handling the concrete.
10. The mixing platform should be washed at the end of the day.
Precautions during Hand Mixing of Concrete
Certain tips, measures that must be taken care while mixing concrete by hand is mentioned
below:

1. The Hand Mixing procedures have to be carried out only for small concrete works. Large works
will ask for large quantity of concrete at a time, for which we must use either a machine mixer or
ready mix concrete.
2. The hand mixing must be employed only for works that will give adequate interval time for
mixing between the work. This means we must not mix large quantities very earlier for a work
that is going to start later.
3. The mixing procedure have to be conducted on a water tight platform. This platform have to be
impervious. This can be either a concrete platform or a brick floor.
4. The floor must have the space to take one bag of cement at a time and their respective materials
(water + aggregate).
5. Initially, the measured quantities of cement and fine aggregate is mixed properly over the
watertight platform. The mixing is continued till a uniform mixture is obtained.
6. The coarse aggregate has to be placed over this bed of uniform mixture. An inappropriate order of
addition of material must not be followed.
7. The addition of water must be done in intervals and not in a single stretch.
8. The whole mixing must be done neatly and uniformly without a hurry.
9. A good and clean showel should be used for the mixing procedure.
10. During hand mixing, it is recommended to avoid large buckets for measurement. Use of large
buckets will end up having a large heap that is difficult to be mixed by hand. In some cases, the
large heap is divided into two large heaps and performed individually. This can be only carried
out by one will proper skill and experience.
 11. Every time after the use, the worming space have to cleaned and made free from any debris.
12. The main issue faced in hand mixing is the addition of too much water that required. This must be
avoided.
13. The workers carrying out the concrete mixing are asked to use masks so as not to inhale the
powder, which can cause serious issues as time passes.
14. For inside concrete works, avoid the hand mixing procedure in the outside or direct sun. This
increase in temperature will evaporate the water content, hence making the mixture dry.
15. Over mixing of the concrete mixture have to be avoided. Once the required amount of mixing is
performed, keep it idol and mixing in small quantities during the time of placing.

Machine mixing of Concrete

There are two broad types of concrete mixers:

1. Batch mixers
o Drum Types Mixer
 Tilting drum mixers
 Non-tilting drum mixer
 Reversing drum mixer
o Pan Type Mixer
2. Continuous mixers

Batch Concrete Mixers

Batch mixers are widely used machines for concrete mixing. Concrete mix
obtained by this mixer is collected batch by batch and time by time. So, it is
called as batch mixer. After pouring all the materials into pan or drum, it mixes
all of those for some time and finally discharges. This process is repeated until
required amount of concrete mix is obtained.

In general Batch mixers are two types.

 Drum type mixers

 Pan type mixers
Drum Type Mixers
In case Drum type mixers concrete ingredients are mixed in a drum which is
actually in double conical frustum shape.

Drum types mixers are classified into three types:

 Tilting drum mixers

 Non-tilting drum mixers
 Reversing drum mixers
Tilting Drum Mixers
Tilting drum mixer means the drum will discharge concrete by tilting
downwards. It is rapid discharge process and used for larger projects. Rapid
means it delivers concrete by gravity that is tilting the drum downwards because
of this the concrete mix obtained will be not subjected to segregation.

Low workable concretes which contains large sized aggregates of size greater
than 7.5cm are also mixed efficiently with this tilting type mixers.

But the mixing efficiency depends on some of the factors as follows:

 Shape of the drum

 Angle of the drum
 Size of blades
 Angle of blades
The only disadvantage of this mixer is sticking of concrete to bottom of drum.
To overcome this a method called buttering of mixer is applied in which some
amount of cement mortar is mixed in the mixer before mixing first batch of
concrete.
Non-Tilting Drum Mixers
Non- tilting drum mixers are not allowed to tilt and the drum rotates about its
horizontal axis. For the discharge of concrete a chute is arranged in inclined
position which will receives the concrete mix from drum and discharges out.

In this case, the drum is opened at two ends and consists blades insides when
materials are poured through one end and mix is collected through another end.

Rapid discharge of concrete is not possible in this case. Due to this delay, the
concrete may be vulnerable to segregation.

The larger size aggregate is not discharged easily with the mix. So, size of
aggregate mot more than 7.5cm is preferable for this type of mixers. So, this
type of mixers are generally used for small projects.
Reversing Drum Mixers
Reversing drum mixers are similar to non-tilting type mixers but in this case
reversal of rotation takes place for different action. The drum has two openings,
one end is for pouring materials and other end is for discharge of mix. The drum
rotates about its horizontal axis. The rotation of drum takes place in one
direction for mixing and in opposite direction for discharging. Two different set
of blades are arranged for mixing and discharging. They are suitable for dry
concrete mixes.
Pan Type Concrete Mixers
Pan type mixers consists a circular pan in which concrete is mixed. The mixing
is done by blades which are arranged in star shape inside the pan.

There are two types of pan mixers are available. In one case, the circular pan is
constant and only star blades rotate about vertical axis of pan. In the other case,
circular pan rotates while the blades are at static position.

But in both cases, the mixing is efficient and concrete mixture is collected
through central hole provided in the pan. The rotating star blades contains
special blades called scrapper blades which will make concrete not to stick to
the pan.

The blades can also be adjusted in height so, there is no room for concrete to
store in the pan. We can say among the all types of batch mixers pan type mixer
are more efficient.
Continuous Concrete Mixers
Continuous mixer, the name itself telling its duty that the loading, mixing and
discharging of mix is continuously done until the work is complete or work
break occurs. The loading of materials is done continuously by screw feeders.

Continuous mixtures are used for very large projects such as dams, bridges,
construction of high rise buildings, etc.