1

Concrete Casting
The result is concrete evidence of
workmanship
2
Topics
Preparation
Securing props
Safety inspection
Casting columns
Casting beams

Casting slabs
Mixing
Curing


3
Preparation
Wash the joints
Remove dirt, soil
Wire brush bars
Check alignment
Secure props

4
Wire brush bars
If the bars are old and rusty wire brush
them. The cement cannot bond with the
steel if it is covered with a thick layer of
rust.
If the bars are factory new wait until they
start corroding. The black surface of new
bars does not bond with cement either.
5
Wash Joints and Formwork
6
Check Alignment
If the formwork is out
of alignment the
concrete will be too
and will have to be
demolished. Take care
that the formwork
cannot give way to the
heavy concrete.
7
Casting Columns
Large columns cannot be cast from the top.
The heavier aggregates would drop to the
lower section and the cement and water
would float on top. This would cause voids
which are called honey combs. These
weaken the structure and are unacceptable.
8
Cut a window into the Formwork of
Columns to cast the lower Part
Then close
the window
and cast the
upper part
9
Section Casting
Especially for fair face
concrete the
expensive formwork
is reduced in size and
used repeatedly. This
avoids also honey
combs since casting
and vibrating is easier
10
Pre-treat the joints
Treat the joint first with
some cement grout
before you cast the
concrete to ensure
better bonding
11
Check Verticality
While casting check verticality and
straightness. You may otherwise get a
terrible surprise since tilted columns cannot
be altered after casting

12
Evenness
Level the concrete along the upper edge of
the formwork after vibrating. Add some
grout and float the surface until it is even.
13
Casting Beams
Set up scaffolding for the entire
length to be able to work without
hindrance.
Column
Float The Top
To achieve
leveled beam
and edges
15
Check props and alignment
Draw a line and make sure that the beams are
aligned. There is nothing you can change
later. If props are not tightened do it
immediately when you feel they are giving
way. If the concrete starts setting you cant
do it any more.
16
Secure Props
Many sites crashed due to bad prop ups
Concrete weighs 2300kg / cu.M
Set a prop every 60cm and secure it on top
and bottom to prevent slippage

Base on
ground
Wedges
from both
sides
Base plate for
better adjustment
of wedges
Secure props
Steel Props
can be easily
adjusted and
secured with
cross braces
19
Casting Sections
Sometimes beams cannot be cast entirely.
They need to be cast in sections too. Do not
join them in the middle. This is the worst
point. Join them at 1/3 from the support.
1/3
2/3
20
Casting Slabs
It is better to cast the beams in the slab first
to put weight all around and then cast the
slab. Vibrating of the beams can be better
controlled to avoid honey combs.
21
Insert Marker Bars to control
evenness and equal thickness
Lay Planks on the reinforcement to
be able to walk, transport, vibrate,
and level the concrete

23
Concrete Mixing
Concrete Mixer
Timing
Handling
24
Concrete Mixer
Thilna Enterprises
25
Vibrate until air
bubbles popping
stops
Vibrate evenly along
the formwork
About Vibration..
26
Over vibration
Over vibration is dangerous to the concrete
Aggregates settle to a sediment at the
bottom, cement and sand collect at top
27
Over vibration
As a result aggregate would not bond and
remain weak and break
See that the aggregates remain visible on
the top!
28
Under Vibration
If the concrete is not sufficiently vibrated
air bubbles remain between the aggregates
and become later visible as honeycombs!
29
Under Vibration
These honeycombs are specially
unacceptable for fairface concrete.
Honeycombing is also the cause for water
leakage
30
Honey Combs