003 Bt3-Manufacturing of Concrete by Art

PREPARED BY ADRIAN R.
TOISA
MANUFACTURING OF
CONCRETE
PREPARED BY ADRIAN R. TOISA
MANUFACTURING OF
CONCRETE
Intended Learning Outcome
1) Discuss the manufacturing of concrete
2) Identify and explain the process of batching of concrete.
3) Identify and explain the classification of mixers.
4) Identify suitable materials used to manufacture concrete.
5) Identify and describe necessary work tools and

equipment in manufacturing of concrete.
VARIOUS STAGES OF MANUFACTURING OF CONCRETE
BATCHING
MIXING
TRANSPORTING
PLACING
COMPACTING
CURING
DRYING

BATCHING
Batching is the "process of weighing or volumetrically measuring and introducing

into the mixer the ingredients for a batch of concrete" (Kosmatka, 94).
Two kinds of process:
a) Volume Batching
b) Weight Batching
Figure
Batching plant
BATCHING  Volume Batching

• This method is generally adopted for
small jobs .
• Gauge boxes are used for measuring the
fine and
coarse aggregate.
• The volume of gauge box is equal to the
volume of one bag of cement.
• Gauge bow are also called as FARMAS
• They can be made of timbers or steel.
• They are made generally deep and narrow
• Bottomless gauge boxes are generally
avoided.
• While filling the gauge boxes the material
should be filled loosely, no compaction is
allowed.
Figure
Farmas used in volume batching of concrete

BATCHING
Volume Batching
Volume Batching
1) The concrete ingredients are batched / proportioned based on volume.
2) Batching by volume achieved by using a constructed gauge boxes (Farmas) for

proportioning the materials according to various mix proportions and based on
the quantity of material needed per batch.
In small works gamellas are also used for batching. But it is not recommended for
batching of concrete.
3) When batching by volume is used, possible sources of error could lead to

variation in the amount of aggregate in a specific volume and errors in measured
volume. These errors often lead to variations in the fresh and hardened properties
of concrete as against specified characteristics properties.

BATCHING
Volume Batching
Volume Batching
4) Variations in quantity are very much likely for materials. ultimately affect
strength of concrete.
5) The volume of water required for mixing is not often specified. Sometime extra
water is added to make concrete workable.
This makes concrete non uniform and reduce the strength.
6) Difficult to detect overruns or incorrect dosages.
7) Slump varies from low to high.
8) For same mix proportion, the compressive strength of concrete batched by

volume is lower than that batched by mass at all w/c ratios and for curing ages 7
to 28 days.
BATCHING
Volume Batching
Volume Batching
9) Admixtures are batched directly into correct mix, which could slow batching
cycle.
10) Admixtures are difficult to batch at certain stages of the batching sequence.
11) The quality of concrete may differ because of bulkage of fine aggregates (Sand)
and therefore concrete is not uniform and consistent.
12) Less precise method. No need to required skilled labors. Easy to operate.
13) Speed of construction is slower than weigh batching.
14) Maintenance cost is practically nill.
15) This method is cheaper and economical.

BATCHING
 Weight Batching
Batching by weight is more preferable

to volume batching ,as it is more accurate and
leads to more uniform proportioning.
It does not have uncertainties associated with
bulking.
It’s equipment falls into 3 general categories :
I. Manual
II. Semi automatic
III. Fully automatic

Figure
Sample batching machine

BATCHING
Manual Batching Equipment
Batching equipment is charged

by devices that are actuated
manually, with the accuracy of the
weighing operation being
dependent upon the operator’s
visual observation of the scale.
The charging device is actuated

by either hand or by power assists
Figure
Manual weight batcher

BATCHING
Semi Automatic Batching

Equipment
Batching equipment is
charged by devices, which are
separately actuated manually
for each material to allow
weighing of the material.
They are actuated

automatically when reaching
the designated mass (weight)
of each material.
Figure
1) Elkon mobile concrete batching
PREPARED BY ADRIAN R. TOISA 2) A semi-automatic small-sized batching plant of Haomei Company.
BATCHING
Automatic Batching
Equipment
Batching equipment is
charged by devices which
when actuated by a single
starter switch, will
automatically start the
weighing operation of all
materials consecutively and
stop automatically when
reaching the designated mass
(weight) of each material. Figure
Fully automated batching plant with multiple mixer and bulk bins.

BATCHING
Weight Batching
Weight Batching
1) The concrete ingredients are batched/ proportioned based on weight.
2) Batching by mass is achieved by using weigh batching machine/ plant.
3) Nominal mix is batched by mass using regularly maintained and well-

calibrated equipment, therefore high degree of uniformity in proportion of the
fresh and hardened state concrete can be achieved.
4) Materials batched by mass are exact in measurement taking cognisance of the

differences in the material properties.
5) Water for mixing is weighed out precisely as a function of the weight of cement
used for each mix proportion. Hence uniform water-cement ratio can be
maintained, which plays an important role in achieving strength of concrete.

BATCHING
Weight Batching
Weight Batching
6) Each batch is weighed which makes it easy to detect overruns or incorrect

dosages.
7) The slump of concrete batched by mass is higher than batched by volume for
same mix proportion and water cement ratios. i.e. slump varies from medium to
very high slump.
8) For same mix proportion, the compressive strength of concrete batched by mass
is higher than that batched by volume at all w/c ratios and for curing ages 7 to 28
days.
9) Admixtures are pre-weighed then held in the hoppers ensuring rapid discharge
with no impact on batch cycle

BATCHING
Weight Batching
Weight Batching
10) Admixtures can be dosed at any stage of batching and in multiple dumps-
thereby achieving optimal performance.
11) Concrete is of uniform and consistent quality.
12) More precise method. Need skilled labors. Operation difficult.
13) Speed of construction is high.
14) Maintenance cost is high.
15) This method is expensive.

MIXING
Mixing concrete is simply defined as the blending of the materials

which are required for the production of a homogeneous concrete.
The mixing should be ensure that the mass becomes Homogeneous,

uniform in color and consistency.
Methods of Mixing :
a) Hands (using hand shovels)
b) Stationary Mixers
c) Ready mix concrete

MIXING
Hand Mixing
Mixing ingredients of
concrete by hands using
ordinary tools like, hand
shovels etc. This type of
mixing is done for Less
output of concrete.
This is probably only suitable

where less than about ¼m³ of
concrete is required for a job
providing that a reasonably fit
person is available.
Figure
Hand mixing
MIXING
Stationary Mixer/ Machine Mixing
A concrete mixer (often mistakenly

called a cement mixer) is a device
that homogeneously combines
cement, aggregate such as sand or
gravel, and water to form concrete.
A typical concrete mixer uses a

revolving drum to mix the
components. For smaller volume
works portable concrete mixers are
often used so that the concrete can
be made at the construction site,
giving the workers ample time to
Figure
use the concrete before it hardens. Stationary mixer

MIXING
Stationary Mixer/ Machine Mixing
In stationary mixer, the concrete is mixed before it is loaded inside the

truck mixer where the concrete is only agitated.
Stationary mixer also refers to the mixer installed on site where

batches of cement and aggregates are mixed and delivered to the
forms.

MIXING
Ready Mix
Buying in Ready Mix - for

jobs requiring more than
about 2m³ of concrete, it is
probably best (and cost
effective) to buy in a lorry
load of ready mixed
Figure
concrete. Ready mix concrete

MIXING
Ready Mix
Figure
Ready mix concrete
When you order Ready Mixed Concrete, you need to tell the supplier
four things:
The quantity of concrete required
The formulation of concrete required
When you want it delivered
The address and any possible problems with access

MIXING
Ready Mix
Things to consider for the delivery include:
 Where is the lorry going to park ?
 Are you ready for the concrete ?
 If the wheelbarrows will need to go across

bare earth or lawns, you may want to lay
down some boards for them to run over to
avoid them sinking in, marking the lawn or
dropping concrete on the ground. Figure
Ready mix concrete
 'Many hands make light work'

MIXING
Ready Mix
Ready mixed concrete is proportioned and mixed off at the project site
and is delivered to the construction area in a freshly mixed and
unhardened state. It can be manufactured by any of the following
methods:
 Central-mixed concrete – mixed completely in a stationary mixer.

Delivered by: a) Agitator truck; b) Non-agitating truck
 Truck-mixed concrete

MIXING
Ready Mix
Agitator truck
A vehicle carrying a drum or

agitator body, in which freshly
mixed concrete can be conveyed
from the point of mixing to that of
Figure
placing, the drum being rotated Agitator truck
continuously to agitate the
contents.

MIXING
Ready Mix
Non-agitating truck
Ready mixed concrete is proportioned and mixed off at the project site
and is delivered to the construction area in a freshly mixed and
unhardened state. It can be manufactured by any of the following
methods:
 Central-mixed concrete – mixed completely in a stationary mixer.

Delivered by: a) Agitator truck; b) Non-agitating truck
 Truck-mixed concrete

MIXING
Classification Of Mixers
The first type is the drum mixer, which can be classified as non-tilting,
split drum, or titling drum mixers, as well as truck mixers or reversing
drum mixers.
Below are different types of drum mixer:
a) Non-tilting
b) Split drum
c) Tilting drum
d) Reversing drum
e) Drum truck mixer

MIXING
Classification Of mixers
DRUM MIXER
Non-tilting mixer
Single drum rotating about a

horizontal axis. Fixed blades work
the concrete towards the discharge
end of the mixer, in order to
provide a rapid rate of discharge.
Figure
Non-tilting mixer

MIXING
DRUM MIXER
Split drum mixer
The drum, rotating on a horizontal axis, separates into two halves,

allowing the concrete to be discharged cleanly and rapidly. No blades
are required since cohesion to the top and bottom of the drum and
cleats provide adequate charging and mixing.

MIXING
DRUM MIXER
Tilting drum mixer
Most suitable for concrete with large

sized aggregate and, since they have a
rapid discharge rate, are suitable for low
workability concrete. Internal blades lift
and tumble the ingredients onto itself.
Two primary types exist: horizontal (one
end has and opening for charging and a
different end for discharging) and single
Figure
drum (materials are charged and Tilting drum mixer
discharged through a single opening).

MIXING
DRUM MIXER
Reversing drum mixer
Rotate in one direction for mixing and

in the reverse direction for discharge.
One set of blades exists for each

operation. Provide efficient mixing
with very little build up within the
mixer. Are suitable with dry concrete
mixes. Figure
Reversing drum mixer

MIXING
DRUM MIXER
Drum Truck Mixer
Two types: rear discharge and front

discharge. Both utilize fins to mix and
discharge the concrete and are
powered by engine driven-variable
speed hydraulic systems.
Figure
Drum truck mixer

MIXING
The second type is Pan Mixer.
A forced movement pan mixer has blades that are fixed to an assembly
that agitates the concrete throughout the pan as the vertical shaft
rotates. This mixer is most common where stiff or zero slump mixes
are prevalent.
"They have not gained acceptance in ready mix production because of

the small size and reputation for high blade and liner wear"
(Dobrowolski, 18.5).
Pan mixers are most commonly found in precast concrete plants.
Figure
PREPARED BY ADRIAN R. TOISA Drum truck mixer
MIXING
The final type is Continuous Mixer.
A free-falling continuous mixer is a gravity-fed mixer, classified by its

continuous movement.
In this process the charging of materials and discharging of the mixed

concrete is released in one, uninterrupted process.
Continuous mixers utilize a continuous weigh batching system as

well.
Materials are typically fed into the mixer by a conveyor system.
Figure
MIXING
… Continuous Mixer.
This mixer is most suitable when large quantities of mass concrete are
required (i.e. dams, foundations, retaining walls and mass concrete
filling).
Stationary mixers are used in ready-mix concrete plants, while

portable mixers are used on construction sites.
Continuous mixers outperform batch mixers when "minor

adjustments to the workability of the concrete" (Murdock, 151) are
required.
Figure
TRANSPORTING
Transporting the concrete mix is defined as the transferring of

concrete from the mixing plant to the construction site. Keep in mind
that not all concrete is mixed on the actual construction site and could
require some significant travel. This is most common for ready-mixed
concretes. The main objective in transporting concrete is to ensure that
the water-cement ratio, slump or consistency, air content, and
homogeneity are not modified from their intended states.
Figure
TRANSPORTING
Modes Of Transportation
Wheelbarrow or Motorized Buggy Figure

Wheelbarrow
 They are typically utilized on small jobs where the travelling

distance is short and the terrain is good and level.
 You should discharge the whole batch being mixed and minimize
any jolting or vibration during transport in order to avoid segregation
of the mix.
 If the weather is hot and the distance is lengthy, it is very important

that you provide some moist curing.
Figure
TRANSPORTING
Wheelbarrow or Motorized Buggy
 When a wheelbarrow or motorized

buggy is used for the first time, ten
percent of cement and sand should be
added to the first batch since the first
batch of concrete mixed is left within
the mixer and the mode of Figure
transportation. Motorized buggy

TRANSPORTING
Truck Mixer
 Truck mixers are essentially free

fall mixers mounted on a truck
chassis.
Truck mixers either contain

centrally mixed concrete (mixed
completely in a stationary mixer and
then transferred to another piece of
Figure
equipment for delivery) or will mix Truck mixer
the contents during transport
otherwise known as truck mixing.

TRANSPORTING
Truck Mixer
 The travel distance of a truck mixer can range from six to Figure
Truck mixer
fifteen miles. This range can be extended by "dry batching."
 If proper site access is provided for the truck mixer, the

concrete can be discharged alongside the designated pour.
 Chutes are typically used during discharge.
 The time that is estimated for a full truck mixer to

discharge all of its contents takes approximately five
minutes.

TRANSPORTING
Bucket
 A bucket is square or circular

and needs the aid of a crane,
cableway, or hoist so that it can
be moved horizontally or
vertically. This type of
transportation has the
capability to move large Figure
quantities of concrete (up to Overhead concrete transport bucket
eight cubic yards at a time).

TRANSPORTING
Steel Skip
A steel skip is used with smaller

mixers. There are two types, a
wedge-shaped skip with a bottom
opening and a lay back skip. They
also need the aid of a crane,
cableway, or hoist in order to be
transported.
Figure
Wedge-shape steel skip
TRANSPORTING
Chute
 A chute should only be used in

short lengths since concrete
becomes more susceptible to
segregation and drying out. When
they are used, therefore, it is very
important that the concrete mix is
workable and cohesive and
should be re-mixed at the lower
Figure
end by passing down through a Concrete chute
funnel-shaped pipe or drop chute.

TRANSPORTING
Belt conveyor
 A belt conveyor is used for

continuous operations and it is
important that the concrete be
designed for this condition.
 It is recommended that low

slump concrete be used for slower
moving belts and higher slump
concrete by faster moving belts.
 Although this type of transport

can move approximately 100 - 350
Figure
cubic yards per hour Belt conveyor

TRANSPORTING
Belt conveyor
 Another concern is segregation.

Figure
Belt conveyor
Belt conveyors are most commonly used in horizontal directions, but

can be moved in the vertical direction (i.e. up to 35o) with some
adjustments to the conveyors.

TRANSPORTING
Figure
Concrete pump
Concrete Pump
 The concrete pump is a popular choice when transporting concrete

because it is fast and often the most economical choice when
challenged with a congested construction site.
 Most concrete pumps utilize a hydraulic system to displace the

concrete.
Two choices of pumps exist: Static pump and mobile pump

TRANSPORTING
Concrete Pump
 Static pump - generally

preferred when a large volume
of concrete needs to be placed at
a very long distance and there is
limited flexibility at the
discharge end. Also called line
pump or trailer-mounted
Figure
concrete pump. Static concrete pump

TRANSPORTING
Figure
Concrete Pump Mobile concrete pump
 Mobile pump – Also known as a boom concrete pump because it

uses a remote-controlled articulating robotic arm called boom to place
concrete accurately. Used on most of the larger construction projects as
they are capable of pumping very high volume and because of labor
saving nature of the placing boom.

TRANSPORTING
Figure
Concrete Pump Pneumatic placer
 Pneumatic placer – Concrete can be transported through steel

pipelines and compressed air by a pneumatic placer. This placer
basically provides a separate batch of concrete that is shot at a
considerable velocity. This is the key difference between pneumatic
placement and concrete pump placement. This type of transportation is
most common in tunnel work.

COMPACTING
Compaction of concrete is process adopted for expelling the

entrapped air from the concrete.
In the process of mixing , transporting and placing of concrete air is

likely to get entrapped in the concrete.
It has been found from the experimental studies that 1% air in the
concrete approximately reduces the strength by 6%.
If we don’t expel this air, it will result into honeycombing and reduced
strength.

COMPACTING
Methods Of Compaction
Hand Compaction
 Hand compaction is used for ordinary and unimportant structures.

Workability should be decided in such a way that the chances of
honeycombing should be minimum. The various methods of hand
compaction are as given below:
a) Rodding
b) Ramming
c) Tamping

COMPACTING
Hand Compaction
 Rodding - It is a method of
poking with 2m long, 16 mm
diameter rod at sharp corners
and edges. The thickness of
layers for rodding should be 15 Figure
to 20 cm. Compaction by rodding

COMPACTING
Hand Compaction
 Ramming - It is generally
used for compaction on ground
in plain concrete. It is not used
either in RCC or on upper floors. Figure
Compaction by ramming

COMPACTING
Hand Compaction
 Tamping - It is a method in
which the top surface is beaten
by wooden cross beam of cross
section 10 cm x 10 cm. both
compaction and leveling are
achieved simultaneously. It is
mainly used for roof slabs and
road pavements.
Figure
Compaction by tamping

COMPACTING
Mechanical Compaction
 Vibration is imparted to the concrete by mechanical means. It causes

temporary liquefaction so that air bubbles come on to the top and
expelled ultimately. Mechanical vibration can be of various types as
given under:
a) Internal vibration
b) External vibration
c) Table vibration
d) Platform vibration
e) Surface vibration

COMPACTING
 Internal vibration - It is most commonly used technique of concrete

vibration. Vibration is achieved due to eccentric weights attached to
the shaft.
 External vibration - This is adopted where internal vibration can’t

be used due to either thin sections or heavy reinforcement. External
vibration is less effective and it consumes more power as compared to
the internal vibration.
a) Table vibration
b) Platform vibration
c) Surface vibration

COMPACTING
 Table vibration - It is mainly used for laboratories where concrete is

put on the table.
 Platform vibration - It is similar to table vibrators but these are

generally used on a very large scale.
 Surface vibration - These are also called screed board vibrators.

The action is similar to that of tamping. The vibrator is placed on
screed board and vibration is given on the surface. It is mainly used
for roof slabs, road pavements etc., but it is not effective beyond 15 cm
depth.

CURING & DRYING
The terms curing and drying are frequently used interchangeably with
regard to the moisture condition of new concrete slabs.
Curing of concrete is defined as providing adequate moisture,

temperature, and time to allow concrete to achieve the desired
properties for its intended use.
Drying of concrete is defined as providing the proper conditions to

allow the concrete to achieve a moisture condition appropriate for its
intended use. The moisture condition of a concrete slab is of
significant importance for the application of moisture sensitive floor
finishes such as vinyl composition tile, linoleum, wood flooring, and
non-breathable coating like epoxy.

REFERENCES
ACI Manual of Concrete Practice, Part 2: Construction Practices and Inspection PavementsMaterials and
General.
Detroit: American Concrete Institute, 1997.
Dobrowolski, Joseph A. Concrete Construction Handbook (4th Edition). New York: McGraw-Hill, Inc., 1998.
Kosmatka, Steven H. And William C. Panarese. Design and Control of Concrete Mixtures(13th Edition). Illinois:
Portland Cement Association, 1998.
Mindess, Sidney and J. Francis Young. Concrete. New Jersey: Prentice-Hall, Inc., 1981.
Murdock, L.J., K.M. Brook, and J.D. Dewar. Concrete: Materials and Practice (6th Edition). London: Edward
Arnold, 1991.
Popovics, Sandor. Fundamentals of Portland Cement Concrete: A Quantitative Approach, Vol.1: Fresh
Concrete. New York:
John Wiley & Sons, Inc., 1982.
http://gharpedia.com/weigh-batching-vs-volume-batching/
http://www.practicaldiy.com/out-doors-diy/concrete/concrete-mixing.php
Kanare, Howard M., Concrete Floors and Moisture, EB119, 2008, 172 pg.

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PREPARED BY ADRIAN R.

Intended Learning Outcome

1) Discuss the manufacturing of concrete

2) Identify and explain the process of batching of concrete.

3) Identify and explain the classification of mixers.

4) Identify suitable materials used to manufacture concrete.

5) Identify and describe necessary work tools and

PREPARED BY ADRIAN R. TOISA

Batching is the "process of weighing or volumetrically measuring and introducing

Two kinds of process:

BATCHING  Volume Batching

PREPARED BY ADRIAN R. TOISA

1) The concrete ingredients are batched / proportioned based on volume.

2) Batching by volume achieved by using a constructed gauge boxes (Farmas) for

3) When batching by volume is used, possible sources of error could lead to

PREPARED BY ADRIAN R. TOISA

This makes concrete non uniform and reduce the strength.

6) Difficult to detect overruns or incorrect dosages.

7) Slump varies from low to high.

8) For same mix proportion, the compressive strength of concrete batched by

13) Speed of construction is slower than weigh batching.

14) Maintenance cost is practically nill.

15) This method is cheaper and economical.

Batching by weight is more preferable

It’s equipment falls into 3 general categories :

II. Semi automatic

III. Fully automatic

PREPARED BY ADRIAN R. TOISA

Manual Batching Equipment

Batching equipment is charged

The charging device is actuated

PREPARED BY ADRIAN R. TOISA

Semi Automatic Batching

They are actuated

PREPARED BY ADRIAN R. TOISA

1) The concrete ingredients are batched/ proportioned based on weight.

2) Batching by mass is achieved by using weigh batching machine/ plant.

3) Nominal mix is batched by mass using regularly maintained and well-

4) Materials batched by mass are exact in measurement taking cognisance of the

PREPARED BY ADRIAN R. TOISA

6) Each batch is weighed which makes it easy to detect overruns or incorrect

PREPARED BY ADRIAN R. TOISA

11) Concrete is of uniform and consistent quality.

12) More precise method. Need skilled labors. Operation difficult.

13) Speed of construction is high.

14) Maintenance cost is high.

15) This method is expensive.

PREPARED BY ADRIAN R. TOISA

Mixing concrete is simply defined as the blending of the materials

The mixing should be ensure that the mass becomes Homogeneous,

PREPARED BY ADRIAN R. TOISA

This is probably only suitable

A concrete mixer (often mistakenly

A typical concrete mixer uses a

PREPARED BY ADRIAN R. TOISA

In stationary mixer, the concrete is mixed before it is loaded inside the

Stationary mixer also refers to the mixer installed on site where

PREPARED BY ADRIAN R. TOISA