1

Engr Muhammad Ali

Lecturer, Department of Engineering Technology

2
Fresh
Concrete
Process of Manufacture of Concrete
• It is interesting to note that the ingredients of good concrete
and bad concrete are the same.
• If meticulous care is not exercised, and good rules are not
observed, the resultant concrete is going to be of bad quality.
• With the same material if intense care is taken to exercise
control at every stage, it will result in good concrete.
Good Concrete and Bad Concrete
Quality
 Process of Manufacture of
Concrete
• The various stages of manufacture of concrete
• are:
• (a) Batching
• (b) Mixing
• (c) Transporting
• (d) Placing
• (e)Compacting
• (f ) Curing
(g) Finishing.
Process of Manufacture of
Concrete
 Batching
Volume Batching:
• Volume batching is not a good method for proportioning the
material because of the difficulty it offers to measure
granular material in terms of volume.
•Volume of moist sand in a loose condition weighs much less
than the same volume of dry compacted sand.
•The effect of bulking should be consider for moist
fine aggregate.
•For unimportant concrete or for any small job, concrete may
be batched by volume.
 Batching : Volume
Batching
• Volume batching:
Batching : Volume
Batching
 Batching
Weigh Batching:
•Weigh batching is the correct method of measuring the materials.
•Use of weight system batching, facilitates, accuracy,
in flexibility and simplicity.
•Large weigh batching plants automatic weighing equipment.
have
•On large work sites, weigh bucket type of weighing
the equipment's are used.
Batching : Weigh Batching
Batching : Weigh Batching
Batching : Weigh Batching
 Mixing
• Thorough mixing of the is essentialfor
materials production of uniform the
concrete.
• The mixing
ensure that The mass becomes
homogeneous,
should uniform in colour and consistency.
•There are two methods adopted for
mixing concrete:
(i) Hand mixing (ii )Machine mixing
 Mixing: Hand mixing
• Hand mixing is practised for small scale unimportant
concrete works.
• As the mixing cannot be thorough and efficient, it is
desirable to add 10 per cent more cement to cater for the
inferior concrete produced by this method.
• Hand mixing should be done over an impervious
concrete or brick floor of sufficiently large size to take
one bag of cement.
• Spread out the measured quantity of coarse aggregate
and fine aggregate in alternate layers.
 Mixing: Hand mixing
• Pour the cement on the top of it,
and mix them dry by shovel,
turning the mixture over and
over again until uniformity of colour
is achieved.
• Water is taken in a water-can
fitted a rose-head and
sprinkled over the
with and
simultaneously turned
mixture
over.
• This operation is continued
such time a
till good
uniform, homogeneous concrete is
obtained.
Mixing: Hand mixing
 Mixing: Machine Mixing
• Mixing of concrete is almost invariably carried out by
machine, for reinforced concrete work and for medium or
large scale mass concrete work.
• Machine mixing is not only efficient, but also economical,
when the quantity of concrete to be produced is large.
• They can be classified as batch-mixers and continuous mixers.
• Batch mixers produce concrete, batch by batch with time
interval, whereas continuous mixers produce concrete
continuously without stoppage till such time the plant is
working.
 Mixing: Machine Mixing
• In normal concrete work, it is the batch mixers that are
used.
Batch mixer may be of pan type or drum type.
• The drum type may be further classified as tilting, non-tilting,
reversing or forced action type.
Mixing: Machine Mixing
Mixing: Machine Mixing
Mixing: Machine Mixing
Mixing: Machine Mixing
 Transporting : Mortar Pan

• Use of mortar pan for transporation of concrete is

one of the common methods adopted in this country.
• In this case, concrete is carried in small quantities.
• While this method nullifies the segregation to
some extent, particularly in thick members
Greater loss of water, particularly, in hot weather
concreting
 Transporting : Wheel Barrow

• Wheel barrows are normally used for

transporting concrete to be placed at
ground level.
• This method is employed for hauling
concrete for comparatively longer distance
as in the case of concrete road construction.
• If concrete is conveyed by wheel barrow
over a long distance, on rough ground, it is
likely that the concrete gets segregated due to
vibration.
Transporting : Wheel Barrow
Transporting : Crane, Bucket and Rope
way
•
A crane and bucket is one of the right equipment for
transporting concrete above ground level.
•
Crane can handle concrete in high rise
construction projects and are becoming a familiar sites
• Cranes are fast and versatile to move concrete
in big cities.
horizontally as well as vertically along the boom and
allows the placement of concrete at the exact point.
• Cranes carry skips or buckets containing concrete.
Skips have discharge door at the bottom, whereas
buckets are tilted for emptying.
• For a medium scale job the bucket capacity may be 0.5
m 3.
Transporting : Crane, Bucket and
Rope way
Transporting : Crane, Bucket and Rope
way
 Transporting : Truck Mixer and Dumpers

• For large concrete works particularly for concrete to

be placed at ground level, trucks and dumpers or
ordinary open steel-body tipping lorries can be used.
• As they can travel to any part of the work, they have
much advantage over the jubilee wagons, which
require rail tracks.
• Dumpers are of usually 2 to 3 cubic metre capacity,
whereas the capacity of truck may be 4 cubic metre or
more.
Transporting : Truck Mixer and Dumpers
Transporting : Truck Mixer and Dumpers
 Transporting :Belt
Conveyors
• Belt conveyors have very limited applications in
concrete construction.
• The principal objection is the tendency of the concrete
to segregate on steep inclines, at transfer points
or
change of direction, and at the points where the
belt passes over the rollers.
• Conveyors can place large volumes of
concrete quickly where access is limited.
Transporting :Belt
Conveyors
 Transporting :Chute

• Chutes are generally provided for transporting

concrete from ground level to a lower level.
• The sections of chute should be made of or lined with
metal and all runs shall have approximately the same
slope, not flatter than 1 vertical to 2 1/2 horizontal.
• The lay-out is made in such a way that the concrete
will slide evenly in a compact mass without
any separation or segregation.
Transporting : Chute
 Transporting :Skip and Hoist
• This is one of the widely
adopted methods for
transporting concrete vertically
up for multi-storey building
construction.
• At the ground level, mixer
directly feeds the skip and the
skip travels up over rails upto
the level where concrete is
required.
• At that point, the skip
discharges the concrete
automatically on
or operation. manual
 Transporting :Transit Mixer
• Transitmixer is one of the most popular
equipments for transporting concrete over
a long distanceparticularly in Ready Mixed Concrete
plant (RMC).
• In India, today (2000 AD) there are about 35 RMC plants and
a number of central batching plants are working.
They are truck mounted having a capacity of 4 to 7 m3.
• In one, mixed concrete is transported to the site
by keepingit agitated all along at a speed varying between 2
to 6 revolutions per minute.
• In the other category, the concrete is batched at the
central batching plant and mixing is done in the truck
mixer either in transit or immediately prior to discharging the
Transporting
 Transporting :Pumps and
Pipeline
• Pumping of concrete is universally accepted as one of the
main methods of concrete transportation and placing.
• Adoption of pumping is increasing throughout the world as
pumps become more reliable and also the concrete mixes that
enable the concrete to be pumped are also better understood.
• The first patent for a concrete pump was taken in USA in
the year 1913.
• By about 1930 several countries developed and manufactured
concrete pump with sliding plate valves.
• The modern concrete pump is a sophisticated, reliable
and robust machine.
Transporting :Concrete
Pumps
• In the past a simple two-stroke mechanical pump consisted
of a receiving hopper, an inlet and an outlet valve, a piston
and a cylinder.
• The pump was powered by a diesel engine.
• The pumping action starts with the suction stroke drawing
concrete into the cylinder as the piston moves backwards.
• During this operation the outlet value is closed. On the
forward stroke, the inlet valve closes and the outlet valve
opens to allow concrete to be pushed into the delivery pipe.
Transporting :Concrete Pumps
Transporting :Concrete
Pumps
• The modern concrete pump still operates on
the same principles but with lot of improvements and
refinements in the whole operations.
• In this concrete placed in a collecting hopper is fed by
rotating blades into a flexible pipe connected to the
pumping chamber, which is under a vacuum of about 600 mm
of mercury.
• The vacuum ensures that, except when being squeezed
by roller, the pipe shape remains cylindrical and thus
permits a continuous flow of concrete.
• Two rotating rollers progressively squeeze the flexible
pipes and thus move the concrete into the delivery pipe.
Transporting :Concrete Pumps
 Transporting :Pipelines and
couplings
• It is equally important to have correct
diameter of pipeline with adequate wall
thickness pressure
operating for a given
and well designed coupling system for
trouble free operation.
• A poor pipeline can easily cause blockages arising from
leakage of grout. Pushing of abrasive material at high
pressure, through pipeline inevitably creates a great deal of
wear.
• Continuous handling, frequent securing and releasing
of couplings creates wear at joints..
 Transporting :Pipelines and
couplings
• Generally almost all pumped
concrete is conveyed through
125 mm pipeline.
• General rule is that the pipe
diameter should be between 3
to 4 times the largest size of
aggregate.
• Concrete been
has pumped to over m and
400 a of
distance over
A height horizontal
2000 m.
 Pumpable
Concrete
• A concrete which can be pushed through a pipeline is called
a pumpable concrete.
• It is made in such a manner that its friction at the inner
wall of the pipeline does not become very high and that
it does not wedge while flowing through the pipeline.
• Pumpable concrete emerging from a pipeline flows in the
form of a plug which is separated from the pipe wall
by a thin lubricating layer consisting of cement paste.
• For continuous plug movement, the pressure generated by
the flow resistance must not be greater than the pump
pressure rating.
 Pumpable
Concrete
However if the concrete
is too saturated at higher
W/C ratio the concrete
at certain pump
pressures may be such
that wateris
forced out of the
mix, creating an increase
in flow resistance and a
possible blockage.
Design Considerations for
Pumpable Concrete
 Placing Concrete
• It is not enough that a concrete mix correctly Designed
• batched, mixed and transported, it is of
importance utmost theconcrete must be
that
systematic mannerplaced
to yield
in optimum results.
• Placing concrete within earth mould.
Foundation concrete
(example:
for a wall or column).
• Placing concrete within large earth mould or timber
plank formwork. (example: Road slab and Airfield slab).
• Placing concrete in layers within timber or steel
shutters. (example: Mass concrete in dam construction
or construction of concrete abutment or pier).
 Placing Concrete

• Placing concrete within usual from work.

(example: Columns, beams and floors).
• Placing concrete under water.
 Placing Concrete

Placement with Conveyor Belt

Concrete spread evenly

across the subgrade by the
paver before consolidation
and finishing
 Placing Concrete

Curb/Curb and
Gutter
Concrete into
deposited
hopper of slip form curb and
gutter machine which then
extrudes the concrete into
the desired shape
Placing and Finishing Concrete
 Placing Concrete
Concrete Pump
Placing concrete by pump and placing boom.

Placing and Finishing Concrete

Underwater Placement
Methods
• Tremie, Pump, Bottom dump buckets, Grouted preplaced
aggregate (specialized),Toggle bags, Bag work, Diving bell
Basic Recommendations
• Water velocity = 3 m / min.

• Water temperature = 5°C

• w/c = 0.45

• Cementing materials content = 390 kg/m3

• Slump range 150 to 225 mm

 Underwater Placement Methods
• Tremie, Pump, Bottom dump buckets, Grouted preplaced
aggregate (specialized),Toggle bags, Bagwork, Diving
bell

• Basic Recommendations

• Water velocity = 3 m / min.

• Water temperature = 5°C

• w/c =0.45

• Cementing materials content =390 kg/m3

• Slump range 150 to 225 mm

Underwater Placement
Methods

Tremie