Construction Technology and Site Management

Module 2

Production of Concrete
Introduction
• The design of a satisfactory mix proportion is by itself no guarantee of having
achieved the objective of quality concrete work. The batching, mixing, transportation,
placing, compaction, finishing and curing are very complimentary operations to obtain
desired good quality concrete. Good quality concrete is a homogeneous mixture of
water, cement, aggregates and other admixtures. It is not just a matter of mixing
these ingredients to obtain some kind of plastic mass, but it is a scientific process
which is based on some well-established principles and governs the properties of
concrete mixes in fresh as well as in hardened state.

• The production of concrete of uniform quality involves the following five definable
phases.

1. Batching or measurement of materials

2. Mixing of concrete

3. Transportation

4. Placing, compaction and finishing of concrete

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5. Curing
BATCHING OF MATERIALS

A proper and accurate measurement of all the materials used in the

production of concrete is essential to ensure uniformity of proportions and
aggregate grading in successive batches.

The batching equipment falls into three general categories, namely, manual,
semi-automatic, and fully automatic systems.

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MIXING OF CONCRETE MATERIALS
• The object of mixing is to coat the surface of all aggregate particles with cement
paste, and to blend all the ingredients of concrete into a uniform mass. The
mixing action of concrete thus involves two operations: (i) a general blending of
different particle sizes of the ingredients to be uniformly distributed throughout the
concrete mass, and (ii) a vigorous rubbing action of cement paste on to the
surface of the inert aggregate particles. Concrete mixing is normally done by
mechanical means called mixer, but sometimes the mixing of concrete is done by
hand. Machine mixing is more efficient and economical compared to hand mixing.

• As a matter of fact the classification of the mixers is based on the technique of

discharging the mixed concrete as follows:

1. Tilting type mixer

2. Non-tilting type

3. Pan or stirring mixer 4

Mixing Time

It is the time required to produce uniform concrete. The mixing time is

reckoned from the time when all the solid materials have been put in the
mixer, and it is usual to specify that all water has to be added not later than
after one quarter of mixing time.
Capacity of mixer, m3 Mixing time, Minutes

0.8 1.00

1.5 1.25

23 1.50

3.1 1.75

3.8 2.00

4.6 2.25

7.6 3.25
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TRANSPORTATION OF CONCRETE
• Concrete from the mixer should be transported to the point where it has to be placed as
rapidly as possible by a method which prevents segregation or loss of ingredients. The
concrete has to be placed before setting has commenced.

• The requirements to be fulfilled during transportation are:

1. No segregation or separation of materials in the concrete.

2. Concrete delivered at the point of placing should be uniform and of proper consistency.

• The prevention of segregation is the most important consideration in handling and

transporting concrete. The segregation should be prevented and not corrected after its
occurrence. The concrete being a non-homogeneous composite of materials of widely
differing particle sizes and specific gravities.

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Pumped Concrete

• Pumping of concrete through steel pipelines is one of the successful

methods of transporting concrete. Pumped concrete has largely been used
in construction of multistory buildings, tunnels, and bridges.

• A modern concrete pump, on the other hand, basically consists of three

parts: a concrete receiving hopper, a controlling valve system and
concrete transmission system.

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READY-MIXED CONCRETE
• A concrete whose constituents are weight batched at a central batching
plant, mixed either at the plant itself or in truck mixers, and then
transported to the construction site and delivered in a condition ready to
use, is termed ready-mixed concrete (RMC). This enables the places of
manufacture and use of concrete being separated and linked by suitable
transport operation. The technique is useful in congested sites or at
diverse work places and saves the consumer from the botheration of
procurement, storage and handling of concrete materials. Ready-mixed
concrete is produced under factory conditions and permits a close control
of all operations of manufacture and transportation of fresh concrete. Due
to its durability, low cost and its ability to be customized for different
applications, ready-mixed concrete is one of the most versatile and
popular building materials.

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Classification of Ready-mixed Concrete
There are three principal categories of RMC. In the first, called the transit-
mixed concrete, the materials batched at a central plant are mixed during
the period of transit to the site or immediately prior to concrete being
discharged. Transit mixing permits a longer haul. Sometimes the concrete is
partially mixed at the central plant and the mixing is completed en route;
such concrete is known as shrink-mixed concrete. This enables better
utilization of transporting trucks. The time of transit after water is added is
generally limited from one to one-and-a-half hours. The total number of
revolutions during both mixing and agitation are limited to 300. In the third
category called the central-mixed concrete, the mixing is done at a central
plant and the mixed concrete is delivered generally in an agitator truck,
which revolves slowly so as prevent segregation and undue stiffening of the
mix.

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Inspection and Testing
• Since RMC is a manufactured product specific control tests and evaluations are
required during the manufacturing process to produce predictable high quality
concrete. Some of the important properties of concrete that are measured by basic
quality control tests are strength, temperature, slump, air content, and unit weight.

• Site Requirements and Preparation Prior to delivery of the concrete, the

contractor/user must ensure that appropriate site preparations have been made.
These preparations should include that:

1. The specified RMC mix is appropriate for the job.

2. The site can utilize/place the concrete at the agreed delivery rate.

3. Acceptance procedures for the RMC are agreed and documented.

4. Site personnel are trained in the specific requirements for placing RMC.

5. Formwork is properly prepared.

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PLACING OF CONCRETE
• The methods used in placing concrete in its final position have an important effect on its
homogeneity, density and behavior in service. The same care which has been used to
secure homogeneity in mixing and the avoidance of segregation in transporting must be
exercised to preserve homogeneity in placing.

• To secure good concrete it is necessary to make certain preparations before placing. The
forms must be examined for correct alignment and adequate rigidity to withstand the
weight of concrete, impact loads during construction without undue deformation.

• Where fresh concrete is required to be placed on a previously placed and hardened

concrete, special precautions must be taken to clean the surface of all foreign matter and
remove the laitance or scum before the fresh concrete is placed.

• It is becoming increasingly more economical place concrete in deep lifts. This technique
saves time and reduces number of horizontal joints. For placing in deep lifts to be
successful, the mix must be designed to have a low risk of segregation and bleeding.

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COMPACTION OF CONCRETE
During the manufacture of concrete a considerable quantity of air is
entrapped and during its transportation there is a possibility of partial
segregation taking place. If the entrapped air is not removed and the
segregation of coarse aggregate not corrected, concrete may be porous,
non-homogeneous and of reduced strength. The process of removal of
entrapped air and of uniform placement of concrete to form a homogeneous
dense mass is termed compaction. Compaction is accomplished by doing
external work on the concrete. The density and, consequently, the strength
and durability of concrete depend upon the quality of this compaction.

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FINISHING OF CONCRETE

The requirements of finishing concrete depend on the type of structural

element and its intended service use, e.g., minimal finishing is required for a
beam, whereas careful finishing is required for flat surfaces like roads and
airport runway pavements; domestic and office floors. The shortcomings in
concrete appearance observed during casting are rectified and concrete is
made to exhibit a pleasant surface finish using special techniques. The
surface finishes are generally grouped in three categories, namely, formwork
finishes, surface treatments and applied finishes.

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CURING OF CONCRETE
• The physical properties of concrete depend largely on the extent of hydration of cement
and the resultant microstructure of the hydrated cement. Upon coming in contact with
water, the hydration of cement proceeds both inwards and outwards in the sense that the
hydration products get deposited on the outer periphery of cement grains, and the
nucleus of unhydrated cement inside gets gradually diminished in volume. At any stage of
hydration, the cement paste consists of the product of hydration (called gel because of its
large area), the remnant of unreacted cement, Ca(OH)₂ and water.

• Therefore, the development of the strength of concrete, which starts immediately after
setting is completed, continues for an indefinite period, though at a rate gradually
diminishing with time. 80 to 85 per cent of the eventual strength is attained in the first 28
days and hence this 28-day strength is considered to be the criterion for the design and is
called characteristic strength.

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FORMWORK

• Though formwork generally forms a part of concrete construction practice,

but as influences the performance of hardened concrete appreciably.

• The formwork or shuttering may be defined as molds of timber or some

other material into which the freshly mixed concrete is poured at the site
and which bold the concrete till it sets. The formwork includes the total
system of support of freshly placed concrete, i.e., form lining and
sheathing plus all necessary supporting members, bracings, hardware and
fasteners.

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• The formwork is planned in such a way that it becomes an integral part of the
total job plan. The above objectives are usually emphasized in the planning. i.e..
the planning for maximum reuse, economical form construction, efficient setting
and stripping practices, and safety from all causes of formwork failure.
• Generally, the butted-and-cleated types of joints are preferable in the construction
of formwork. All the formwork should be so designed and constructed that it can
easily be stripped in the desired order after the setting of concrete, and no piece
of formwork gets keyed into the mass of concrete. The shuttering must be
chamfered at the junctions to facilitate its free and easy withdrawal. If nails are
used they should be driven until they are in the concrete surface and their heads
should be slightly projected outside for easy removal.

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