CONCRETE BATCHING AND MIXING

1. Methods of Batching
Batching is the process of measuring and combining required ingredients of concrete by either by weight
or by volume as per the mix design and introducing them into a mixture to produce a uniform quality of
concrete.

1.1. Batching by Weight

 In this method, materials are measured on the basis of weight. It is accurate method of
batching.
 Weight batchers or other types of weighing equipment are used to measure weight of materials.
 Cement, fine aggregates, course aggregates and water are taken by weighting.
 Weigh batchers used are available in two types namely mechanical weigh batcher and electronic
batchers.
 In mechanical weight batchers, weights are measured using spring and dial gauge arrangements
and it is widely used equipment in weigh batching.
 In electronic weigh batchers, electronic scales and load cells supported by hoppers are used to
measure the weight of ingredients of concrete.
 Weigh batchers available may be manual or semi- automatic or fully automatic. Manual type is
used for small concrete production while other two types are used for large concrete
production.

Figure 1: Semi-Automatic Weigh Batcher

 In semi-automatic weigh batching, aggregates containers gates are lifted manually and it is
automatically closed after reaching the required quantity in weighing machine.
 In full automatic weigh batcher, all the process will be done automatically. The benefit of this
type of equipment is, it is also measures the moisture content resent in the aggregates and
corrects the required quantity of water-cement with respect to the moisture content of the
aggregates.
 To prepare 1:1:2 concrete mix using weigh batching, measures quantity of materials is 50kg of
cement, 50kg of fine aggregates and 100kgs of course aggregates

Figure 2: Automatic Weigh Batcher

1.2. Batching by Volume

 In volume batching, the materials are measures on the basis of volume. It is less precise method
of batching
 Measurement Boxes or gauge Boxes of known volume are used to measure materials.
 Cement is taken in the form of bags, where the volume of one bag of cement(50kgs) is taken as
35litres. Cement should not be batched by volume because its weight per unit volume varies
according to the way the container is filled.
 The volume of the Gauge Box used is made equal to the volume of one bag of cement which is
35ltrs or multiples thereof.
 Gauge Boxes are generally deeper and contains narrow top surface and they are made of timber
or steel or iron.

Figure 3: Gauge Box or Measuring Box

  Volumes of different sized fine aggregates and course aggregates are measured individually by
these gauge boxes.
 Water is measured using water meter or water cans of known volume used.
 To make 1:1:2 ratio concrete mix according to volume batching, one should take one bag of
cement (35litres), 1-gauge box of fine aggregates (35litres) and 2 Gauge Boxes of course
aggregates(70litres).
 If the water-cement ratio is 0.5, then half the volume of cement which is 17.5litres should be
taken

Advantages of Volume Batching

 It is easy to carry out

 It is economical on small sites

Disadvantages of Volume Batching

 Volume batching is not a good method for measuring concrete materials.

 It is not applicable in case of reinforced concrete structure.
 This method of concrete batching may not be economical.
 It can be only used for unimportant concrete or for small concrete works.
Figure 4: Sizes of Gauge Boxes

Figure 5: Conversion of Volume to weights Proportions

2. Common Mixing Ratios
 3. Methods of Mixing
The main objectives of mixing concrete are:

i. To coat the surface of all aggregates with a cement paste

ii. To blend all the ingredients of concrete into a uniform mass

There are two methods used in mixing concrete namely;

 Hand mixing
 Machine mixing

3.1. Manual/Hand Mixing

A batch to be mixed by hand should be in relatively small (affordable) amounts. The equipment consists
of a mixing platform, two shovels, a metal-lined or wooden measuring box and a graduated bucket (or
any container with a known capacity such as the common 20-liter jerry can) for measuring water.

The mixing platform used should be level, water tight and clean before use. It can be;

 An abandoned concrete slab

 A concrete packing lot that can be cleaned after use.
 Wooden platform having tight joints to prevent loss of water.
 A platform made of brickwork or stone masonry with joints sealed to prevent water loss

Procedure for hand mixing

i. Place the measured quantities of course and fine aggregates on a raised ground on site.
ii. Measure the correct portions of cement
iii. Put it on top of a heap of aggregates and spread evenly with a mixing shovel.
iv. A measured amount of water is then added while mixing.

However, the following is the most commonly used hand mixing procedure on construction sites:

i. Place the measured quantity of sand (fine aggregates) on the clean platform and spread it out in
a layer of uniform thickness
ii. Place cement over the sand and spread out uniformly.
iii. Mix the fine aggregates with cement using a shovel
iv. Turn the mix from side to side as many times as possible to produce a uniform color throughout.
Workers doing the mixing face each other from opposite sides of the heap and work from the
outside to the center.
 v. After the uniform color is got, spread the mixture on the plat form and pour course aggregates on
top
vi. Use the watering can or a hose to add water while mixing. Care should be taken to ensure that
neither water by itself nor with cement can escape.
vii. When all the water has been absorbed, the mixing is continued until the mix is of uniform
consistency. No soil or other extraneous material must be allowed to become included in the
concrete.

Advantages of hand mixing

 It is cheap for smaller jobs

 It is the best alternative for unskilled personnel

Disadvantages of hand mixing

 Time consuming
 It is sometimes hard to get a uniform mix
 It is cost y for big jobs (in terms of labour)

3.2. Machine Mixing

This involves drum types of machines and each drum has its own capacity chosen to meet the required
quantities on a particular job and the speed to which each batch can be laid.

Water is first added and this moistens the drums and removes any concrete adhering to the sides. The
remaining materials are then measured into the drum in their correct proportions. The loaded drum is
allowed to mix for about 2 – 5 minutes and concrete is then ready for discharge.

The concrete is released from the drum depending on the type of the drum. It is released to the cart or
wheel barrows or dumper and driven to the site for placing.

Advantages of machine mixing

 It is very fast
 Produces a better mixture

Disadvantages of machine mixing

 High initial costs

 May result in poor workmanship
 Requires skilled personnel to operate the machine

General principles in the use of concrete mixers

1. It is an advantage to feed cement, sand and coarse aggregates in the mixer simultaneously and in
such a way that the flow of each extends over the same period.
2. The water should enter the mixer at the same time and over the same period like the other
materials. With many mixers, this is not possible since the rate of flow is limited. In such case it is
advisable to start the flow of water earlier.
3. Mixing should continue until the concrete is of uniform consistency and color.