CONCRETE HANDLING IN THE

FIELD
By K.Shah
B.E.(Civil Engg) NIT Rourkela,India
M.Sc. (Environment), University of Leeds, UK
Ex-GM(Civil & Environment) MNC
Currently Guest faculty-College of Technology &
Engineering

KAS-2012 1
Stages of producing concrete.

(1) Batching
(2) Mixing
(3) Transportation
(4) Placing
(5) Compacting
(6) Curing
(7) Finishing
KAS-2012 2
(1) Batching

(a) Volume batching

(b) weight Baching

KAS-2012 3
Volume batching
Volume batching is not good method
Moist sand in loose condition weights less
than the same volume of dry sand.
Practiced for small work.
For quality work ,weigh batching is
practiced.

KAS-2012 4
 VOLUME BATCH
Gauge box
Various gauge boxes of different volumes are
used.
Length Width Depth Volume
33.3 cm 30 cm 20 cm 20 liters
33.3 cm 30 cm 25 cm 25 liters

Grade Cement- kg Sand -lts Coarse

Aggregate
lts
1:11/2:3 (M 50 35 70
200)
1:2:4 (M 50 70 140
150)
1:3:6 (M100) 50 105 210

KAS-2012 5
Weigh Batch Machine

KAS-2012 6
Weigh batching
Weigh batching is correct method
Facilitates accuracy, flexibility & simplicity

Different batching machine are available :

(a) manual machines & (b) Automatic machines
Manual machine :
Has two buckets
Buckets mounted on common spindle about which they rotate.
One is loaded while other is discharged in mixer.
Spring loaded dials indicate the weight.

KAS-2012 7
Automatic weigh batch
For large works
Over head hopper and discharges into
mixer.
Useful in ready mix concrete plant
Recorders for weight
Calibration is required from time to time.

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(2) MIXING
Mixing of cement,sand aggregates should
ensure that:
The mass is homogeneous
Uniform in color
consistent

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 MIXING METHODS :

(1) Hand mixing

(2) Machine mixing

KAS-2012 10
Hand mixing
Practiced for small scale work (small
house, repairing of house etc)
10 % extra cement is added to
compensate inferior concrete produced by
this method.
Spread fine & coarse aggregate in
alternate layer
Spread cement over it
Mix with shovel till uniform color is
achieved KAS-2012 11
Machine mixing
Medium & large scale work use machine
mixing
Mixing is efficient, economical & produce
quality concrete.
Type of mixer:
(a) Batch mixer : batch by batch with time
interval
(b) Continuous mixer: continuously mixed &
discharged (in dam construction)
KAS-2012 12
CONCRETE MIXER
(1) Pan type
(2) drum Type:
(a) tilting
(b) Non tilting
(c) Reversing

KAS-2012 13
PAN MIXER

KAS-2012 14
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.

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 DRUM MIXER
As per IS: 1791-1985 mixers are
designated by number which shows
capacity (liters) of batch:
a) Tilting : 85 T, 100T, 140 T, 200T
b) Non tilting : 200 NT,280 NT, 375 NT, 500
NT, 1000 R
c) Reversing : 200 R, 280 R, 375 R,500 R,
1000 R
T= Tilting, NT =non tilting, R=Reversing
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TILTING MIXER

KAS-2012 17
TILTING MIXER
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)
single drum (materials are charged and
discharged through a single opening).
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NON TILTING MIXER

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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.

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REVERSING MIXER

KAS-2012 21
REVERSING MIXER
The entire drum rotates around its axis as
materials are loaded through a charge chute at
one end of the drum and exit through a
discharge chute at the opposite end of the drum.
Mixing blades are mounted on the inside surface
of the drum and as the drum rotates the blades
mix by lifting and dropping the materials during
each rotation.
Once the materials are sufficiently mixed the
rotation of the drum is reversed and the blade
arrangement pushes the concrete through to the
discharge end of the mixer.
KAS-2012 22
Sequence of charging drum
First half quantity of coarse aggregate is
placed in skip
Over it half quantity of sand
On that full quantity of cement
Over it balance quantity of coarse & fine
aggregates is place.
This prevents spillage of cement in air
while discharging in drum
KAS-2012 23
 25 % Water is placed in drum and then
mix from skip is discharged in the drum
This prevents sticking of cement on blades
75 water is immediately poured after
placing mix material (cement sand etc) in
drum.

KAS-2012 24
Mixing time
In small machine, mixing time varies
between 1-2 minutes
In Ready Mix Cement mixer 15-30
seconds
RPM of drum : 15-20
Compressive strength of concrete
increases with increase in mixing time but
after 2 minutes increase in compressive
strength is not significant.
KAS-2012 25
 If concrete is not used after mixing it may
set
But when concrete is agitated on time to
time in drum setting time rule does not
follow.

KAS-2012 26
Retempering of concrete :

Some time concrete from RMC plant is not

delivered to site due to traffic congestion
Concrete becomes stiff and becomes
unworkable
Site engineers can reject the concrete if
delay is more
If it can be of used then small volume of
water is added and again agitated in the
drum. This is called RETEMPERING OF
CONCRETE. KAS-2012 27
MANUFACTURING OF
CONCRETE

With same material if care is not taken,

resulting concrete will be bad concrete
What are good rules to make good quality
concrete.

KAS-2012 28
 TRANSPORTATION OF CONCRETE

Precaution in concrete transportation:

Homogeneity of conc. Mass is maintained
Movement of hand trolly or truck on rough
road surface makes vibrations
This results in deposition of heavy
aggregates at bottom of truck
Water & cement slurry comes on top.

KAS-2012 29
METHODS OF TRANSPORTATION

1. Mortar Pan
2. Wheel barrow
3. Truck Mixer & dumpers
4. Crane, Bucket & rope way
5. Belt conveyors
6. Chutes
7. Skip & hoist
8. Transit Mixer
9. Pump & pipeline
10. Helicopter

KAS-2012 30
 MORTAR PAN
Common method in India
More labour required
Segregation of concrete is less
Greater surface area of concrete is
exposed to sun, concrete dries.

KAS-2012 31
 WHEEL BARROW

When transportation of concrete is at

ground level.
Movement of wheel on rough road
surface, segregates concrete.
Some wheel barrows have pneumatic
wheel to reduce vibration

KAS-2012 32
 CRANE

Used for transporting concrete above

ground level.
For high rise buildings.
Cranes are fast
Can move horizontally & vertically
Concrete in skip discharge from bottom
In bucket concrete is discharged by tilting.

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 BUCKET & ROPEWAY
Use for construction in:
Valley
Bridge pier in river
Dam
Advantage:
Concrete is not exposed to sun or air & no
loss of water.
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 Truck Mixer & dumpers
Used for large concrete works.
Can travel any part of site.
Dumpers - 2-3 M3 Capacity
Trucks 4 M3 Capacity
Bottom surface of truck is kept wet
Top of truck is covered to prevent
evaporation
KAS-2012 35
 BELT CONVEYORS
Limited use in construction

Advantages:

Can transport large volume

Very quick
Can go where access is limited

Disadvantages :

On steep slope concrete segregates.

Exposed to sun for long time.

KAS-2012 36
 CHUTE
For transporting from ground level to lower
level. (basement etc).
Used where labour can not reach due to
less space in trench etc.
Made of metal
Slope should not be < 1 vertical : 2.5
horizontal.

KAS-2012 37
 SKIP & HOIST
Labour can go upto 3rd or 4th floors.
So skip is used for transport vertically up
(in multistory building).
Skip travels on vertical rail.
Skip can discharge manually or
automatically.

KAS-2012 38
TRANSIT MIXER

KAS-2012 39
 TRANSIT MIXER
Used for long distance travel in RMC plant.
Concrete is continuously agitated in truck drum
(2 6 rpm).
Also transported mix in dry condition and water
is added on reaching the destination.
Wet Mix in truck must reach site in 1- 1.5 hours.
Pumps are also fitted on truck mixer to
discharge concrete.

KAS-2012 40
 PUMPS & PIPELINE
Most popular method
Reliable & good quality pumps are used.
Mostly operated by diesel.
Concrete is placed in collecting hopper.
Rotating blades in hopper pushes concrete
towards pipe.
Vacume in hose pipe (600 mm Hg)
Rotating rollers in pump chambers squeeze the
concrete in pipe and flow of concrete is started.
Concrete is discharged from other end of hose
pipe.
Concrete can be pumped upto 400 m height and
2000 m distance.
KAS-2012 41
SECTION OF PUMP

KAS-2012 42
 PIPELINE
Pipeline should :
Have correct diameter as per pump
pressure. (generally 125 mm)
Have sufficient thickness
Good couplings
Poor pipeline can cause blockage.

KAS-2012 43
 PIPELINE
Thumb rule : For 30 M3 /hr concrete and
200 m length, dia should be 100 mm.
Length > 500 m then dia = 150 mm.
Dia = 3 to 4 times the size of aggregate
Leaky pipe & coupling result in escape of
water /air & finally block the concrete.
Vertical pipe should good otherwise
difficult to change at height.
Pump is kept at distance from building
about 15 % of vertical length.
KAS-2012 44
 PUMPABLE CONCRETE
Concrete which can be pushed through a pipeline is
called pumpable concrete.
Friction between pipe wall and concrete is less.
Concrete flows in the form of plug which is separated
from pipe wall by a thin layer of lubricating cement paste.
Flow resistant must be < pump pressure.
If the concrete is more wet then water comes out of mix
which makes more resistance to flow.
Stiff and also very wet concrete is not pumpable.

KAS-2012 45
 Design of pumpable concrete
Concrete Mix is so designed that all material remain
together.
Mix must make redial movement of grout to maintain
lubricating paste.
Mix should be deformed at bends
Cement & fine particles (0.25 mm size) are important for
good flow.
350 to 400 Kg/ M3 of fine particles are necessary for
flow.
Slump of pumpable concrete is above 75 mm.

KAS-2012 46
 PROBLEMS IN PUMPING
Blockage in pipe
Pipe should be cleaned after each day
operation
Blockage can be cleaned by forward-
backward pumping.
Tapping pipe with hammer
Clean pipe with rod or sponge ball pushed
by compressed air.
KAS-2012 47
 PLACING CONCRETE
Must be placed in systematic manner.
Can be placed with following methods:
Within earth mould : Foundation
In timber plank formwork : Road, airport
slab.
Steel shuttering : Dam
Under water

KAS-2012 48
 Concrete in Foundation
In foundation, ground is made wet.
Plastic sheet are laid between ground & slab
Concrete is dumped not poured.
No heap and dragging
Placed in layers of 35 40 cm in mass concrete
Avoid cold joints between 2 layers
Surface of previous layer is cleaned with wire brush
Sometime, cement slurry is placed on old surface
Top of previous layer kept rough for good bond.

KAS-2012 49
Concrete on Road, airport, floor slabs

Placed in alternate bays (allow shrinkage)

with contraction joints :

contraction joints

Bays

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 Concrete in Beams & Column
Reinforcement correctly placed.
Correct cover required
Joints of shuttering to be plugged.
Mould releasing agent inside formwork

KAS-2012 51
 STRIPPING TIME
Form work should not removed until good
strength has come.

Type of form work Time

Vertical wall, columns 16-24 hrs
Soffit of slab (Prop should be refixed immediately) 3 days
Soffit of beam (Prop should be refixed immediately) 7 days
Props to slab Span < 4.5 m 7 days
Props to slab Span > 4.5 m 14 days
Props of beam (Span < 6 m) 14 days
Props of beam (Span > 6 m) 21 days

KAS-2012 52
UNDER WATER CONCRETE

KAS-2012 53
 UNDER WATER CONCRETE

Tremie (means hopper) is used.

Funnel on top
Pipe of 200 mm size
Pipe bottom is plugged
Fill pipe with concrete
Lift pipe or jerk to release the plug
Keep bottom of pipe inside concrete

KAS-2012 54
 Underwater Concrete
No compaction required as hydrostatic pr
of water compacts concrete.
Concrete of 0.3 W/C ratio can be placed
with Tremie.
Used for Pile or well foundation

KAS-2012 55
 SLIP FORM TECHNIQUE
In this method, concrete is continuously placed, compacted & form work is
pulled up for next layer of concrete.
Vertical slip form for Tall structure like silo, chimney
Horizontal slip form paver machine (HSFP) for road construction.
Concrete is dumped in front of HSFP machine by dumpers.
Compaction by vibrator installed inside HSFP machines.
Finishing of surface by HSF paver.
Operation of road alignment, gradient, curve are controlled by
Computerized Laser Control system.
Speed of construction is 1 mt /min.
1 km of concrete road of 3.75 mt width is built in one day (16 hrs work).
Mumbai-Pune Expressway was constructed by this machine.

KAS-2012 56
VERTICAL SLIP FORM

KAS-2012 57
HORIZONTAL SLIP FORM ROAD PAVER

KAS-2012 58
 COMPACTION OF CONCRETE
Compaction is a process of expelling the entrapped air inside
concrete mass.
During mixing, transporting & placing the concrete, air gets trapped
in concrete mass.
If this air is not removed, concrete will not get strength.
5 % of air voids reduces strength by 30 %
10 % of air voids reduces strength by 50 %
Durability of concrete is also reduces with air voids.
Insufficient compaction increases permeability of concrete.
Results in entry of aggressive chemicals in solution.
Chemicals attack concrete & reinforcement and life of concrete is
reduced.

KAS-2012 59
 METHODS OF COMPACTION

1. Hand compaction
2. Compaction by vibration
3. Compaction by pressure &
jolting
4. Compaction by spinning
KAS-2012 60
 (2) COMPACTION BY VIBRATION

a) Internal Vibrator
b) Formwork Vibrator
c) Table Vibrator
d) Platform Vibrator
e) Surface Vibrator

KAS-2012 61
 (1) HAND COMPACTION

Hand Rodding
Poking inside concrete with 1-2 mt long steel rod
Ramming
Unreinforced foundation & ground floor work
Tamping
Wooden beam is used to beat concrete (low
thickness slab, road slab)

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 COMPACTION BY VIBRATION

In hand compaction w/c ratio is more so

we get less strength in concrete.
In mechanical vibrator w/c can be kept low
so we get good strength.

KAS-2012 63
INTERNAL VIBRATOR

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(a) INTERNAL VIBRATOR
Most common in use
Called, Needle Vibrator or Immersion vibrator or
Poker vibrator.
Consists : electrical/diesel power supply, Needle
and shaft.
Frequency of vibrations can be 12000 cycles
vibration per minute.
Needle diameter 20 to 75 mm
Length 25 to 90 cm.
Portable.
KAS-2012 65
FORMWORK VIBRATOR
Used for columns, walls, precast slab
Vibrator is clamped to formwork
Vibration is given to formwork
Vibration is transferred from formwork to
concrete
Useful in thin wall where reinforcement
obstruct the needle type vibrator.
Efficiency is lower then needle vibrator
KAS-2012 66
TABLE VIBRATOR
Vibrator is clamped to table
Used for concrete test cubes
Cubes are kept on table to get vibrations
Also used for small prefabricated slab

KAS-2012 67
TABLE VIBRATOR

KAS-2012 68
PLATFORM VIBRATOR
Similar to table vibrator but of large size
Used for long concrete electrical pole,
railway sleeper,prefabricated roofing
element

KAS-2012 69
PLATEFORM VIBRATOR

KAS-2012 70
SURFACE VIBRATOR
Known as Screed Board Vibrator
Used for thin roof slab where needle
vibrator can not be used
Not effective if slab thickness is more then
15 cm.

KAS-2012 71
SURFACE VIBRATOR

KAS-2012 72
COMPACTION BY PRESSURE & JOLTING

Used for hollow blocks, solid concrete

blocks
Stiff concrete is vibrated, pressed & given
jolts
Stiff concrete is compacted to get dense
form & good strength is achived.

KAS-2012 73
VIBRATION BY SPINNING
New method
Used for concrete pipes
Concrete when spun at high speed gets
compaction by centrifugal force

KAS-2012 74
VIBRATORY ROLLER
Road rollers has vibrating system
Roller while moving on raod slab gives
vibrations
Used for Lean concrete (M10) for road
base

KAS-2012 75
ROLLER VIBRATOR

KAS-2012 76
PRECAUTIONS IN VIBRATING CONCRETE

Vibrator gets damaged if comes in contact

with hard object (Formwork, hard
concrete)
Switch on when needle is inside fresh
concrete mass
Should conform to IS 2505-1963
Degree of compaction can be recognized
from rising air bubbles & formation of thin
film on top
KAS-2012 77
 HYDRATION OF CEMENT
Cement is made by Cao, SiO2, Al2O3, Fe2O3, MgO, K2O,
SO3
After burning in Kiln following products are made:
3Cao. SiO2 (C3S) - Tri calcium silicate
2Cao. SiO2(C2S) Di cacium silicate
3Cao. Al2O3 (C3A) Tri cacium aluminate
4Cao. Al2O3. Fe2O3(C3AF) -Tricalcium alumino ferrite.
On addition of water in cement reaction of C3S, C2S, C3A
& C3AF liberate heat. Heat is suside by addition of water.

KAS-2012 78
 CURING OF CONCRETE
Curing is defined as making satisfactory moisture
content & favourable temperature in concrete after
placing the concrete. So that hydration may continue
until the strength is developed.
Curing is required immediately after placing concrete.
During hydration, heat of hydration is released.

KAS-2012 79
 CURING OF CONCRETE
Concrete delivers its strength by the hydration of cement
particles.
Hydration is continuous & long time process.
Rate of hydration is fast immediately after making the
concrete
Theoretically 0.23 w/c ratio required for hydration
0.15 w/c ratio required for filling the voids in gel.
Total 0.38 w/c ratio is optimum
In field condition, water evaporates & available water
quantity reduced for hydration
Extra water is given by curing
KAS-2012 80
 METHODS OF CURING

a) Water curing
b) Membrane curing
c) Application of heat
d) Other methods

KAS-2012 81
 WATER CURING

a) Immersion : Slab is kept in water tank

b) Ponding: Roof slab is filled with water
c) Spraying : water spary on concrete wall is
d) Wet covering : Wet gunny bags on wall

KAS-2012 82
 MEMBRANE CURING

Concrete surface is covered by plastic

membrane
It is used where water availability is less.
Plastic sheet reduces evaporation in
concrete
Membrane is applied after 2 days of water
curing

KAS-2012 83
 APPLICATION OF HEAT
Spraying of steam on concrete provides heat & moisture.
Higher temperature accelerates hydration rate & strength
of concrete is attended
Early strength of structure is obtained
Steam application possible at precast factory only.
Precast prestressed concrete girders of bridge are cured
with steam
Fast construction of bridge

KAS-2012 84
 HIGH PRESSURE STEAM CURING

Superheated steam at high pressure (8.5 kg/cm2) & high

temperature(175 deg C) is applied on concrete.
This process is called Autoclaving
28 days strength of concrete is achieved in one day
Concrete becomes sulphate resistant
Low shrinkage in concrete
Used in production of Cellular concrete products(
Siporex, Celcrete)

KAS-2012 85
 FINISHING OF CONCRETE
Finishing is last operation of concrete making.
Finishing of top surface is required in roads, airport
strip, home floor
Methods of Finishing:
a) Form work Finish
b) Surface Treatment
c) Applied Finishes

SHAH K.A. 86
 FORMWORK FINISH
Concrete obeys the shape of formwork
Grooves & lining on formwork plate gives
makes grooves & lining on concrete
Prefabricated tiles can be made of any
design
 SURFACE TREATMENT
Domestic floor should be smooth, wear resistant, crack
free.
Mix should have good proportion without excess Matrix
Exposed aggregate finish : Colored pebbles on top layer
of wall
Bush Hammering : Electrically operated Brush with teeth
when applied on concrete removes top cement layer,
exposes aggregates and makes shining aggregates.

KAS-2012 88
 APPLIED FINISH

Rough cast finish : mixture of cement, sand, round

gravel is applied on wall

Non slip finish: Railway platform & walkway around

pool are given non slippery finish by mixing large size
sand particles in floor concrete.