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A batching plant for Ready-Mixed Concrete (RMC) is a specialized facility used to

prepare concrete mixtures according to specified recipes and proportions.
Here are the key details typically associated with a batching plant for RMC:

1. Aggregate Bins: These are storage units for different types of aggregates (like gravel,
sand, and crushed stone) used in concrete production. Batching plants usually have
multiple bins to store various sizes of aggregates.

2. Batching System: This includes equipment for weighing and dispensing the
aggregates, cement, water, and additives into the mixer in the correct proportions.
Modern batching systems are computer-controlled to ensure accuracy and consistency.

3. Cement Silos: These are storage containers for cement, ensuring a continuous supply
to the batching plant. Cement silos can be large enough to hold several tons of cement,
and they often include mechanisms for accurate metering and dispensing.
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4. Water and Admixture Dispensers: Water is a critical component in concrete
production, and batching plants are equipped with systems to measure and add water to
the mix in precise amounts. Admixtures, which are chemicals added to improve the
properties of concrete (e.g., accelerating or retarding setting time, improving
workability), are also stored and dispensed similarly.

5. Mixer Unit: The heart of the batching plant, where all the ingredients are combined
and mixed thoroughly to produce concrete. There are various types of mixers used in
batching plants, such as drum mixers, pan mixers, or twin-shaft mixers, depending on
the desired output and specific requirements.

6. Control System: Batching plants are typically controlled by sophisticated computer

systems that automate the batching process. These systems allow operators to input mix
designs, monitor operations, and adjust parameters as needed to ensure consistent
quality and performance.

7. Batching Plant Layout: The layout of a batching plant can vary depending on its
size and configuration. It includes areas for aggregate storage and handling, cement
silos, mixing unit, control room, and space for loading and unloading of trucks.
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8. Environmental Considerations: Batching plants are designed to minimize

environmental impact, with measures such as dust collectors to control airborne
particles, and water recycling systems to reduce water usage and manage wastewater
responsibly.

 Calibration of RMC Plant

Calibration of equipment in a Ready-Mixed Concrete (RMC) plant is crucial to ensure
accurate measurement and consistent quality of concrete batches.

Types of Equipment Requiring Calibration:

1. Weighing Systems: Calibration ensures that the scales used for weighing
aggregates, cement, water, and admixtures are accurate. This typically involves
verifying the calibration against known weights at regular intervals.
2. Water Meters: Calibration of water meters ensures that the amount of water added
to each batch is precise and consistent. This can involve comparing the meter
readings against a calibrated flow meter.
3. Admixture Dispensers: Admixtures are chemicals added to concrete to modify its
properties. Calibration ensures the correct dosage of admixtures, often by verifying
dispenser settings against a known standard.

Calibration Procedures:
Initial Calibration: When new equipment is installed or after maintenance, initial
calibration ensures that the equipment meets accuracy requirements. This involves
adjusting settings and verifying readings against known standards.
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Regular Calibration: Scheduled at regular intervals (e.g., monthly, quarterly), regular
calibration ensures ongoing accuracy. It involves testing equipment under typical
operating conditions to detect any drift or changes in accuracy.

Emergency Calibration: If there are indications of inaccurate measurements or

unexpected results in concrete quality, immediate calibration checks may be necessary
to rectify the issue promptly.

Steps Involved in Calibration:

1. Preparation: Ensure the equipment is clean, properly maintained, and in a stable

environment suitable for calibration.

2. Adjustment: If deviations are found during calibration, adjustments may be

necessary. This could involve recalibration of sensors, fine-tuning of settings, or repairs
to components affecting accuracy.

3. Verification: After adjustments, verify the equipment's performance by retesting

against standards to ensure accuracy within acceptable tolerances.

Benefits of Calibration:
1. Quality Assurance: Ensures consistent quality and performance of concrete mixes,
minimizing variations and ensuring adherence to specifications.

2. Cost Savings: Accurate calibration reduces material waste and improves efficiency
in concrete production.
3. Compliance: Helps meet regulatory requirements and customer expectations for
quality assurance in construction projects.

Challenges and Considerations:

1. Environmental Factors: Ensure calibration procedures account for environmental
conditions (e.g., temperature, humidity) that can affect equipment performance.
2. Training: Proper training of personnel involved in calibration is essential to ensure
procedures are followed correctly and consistently.
3. Maintenance: Regular maintenance of equipment is crucial to prolong its lifespan
and maintain calibration accuracy over time.
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 PUMPING OF CONCRETE
Concrete pumping is a method of transporting freshly mixed concrete from the mixer to the formwork
using a pump. It is an efficient and economical way of placing concrete, particularly in large-scale
construction projects.

1. Concrete Pumps
a. Types of Concrete Pumps
 Boom Pumps: These are truck-mounted pumps with a robotic arm (boom) that can
be controlled remotely to place concrete accurately.

 Line Pumps: Also known as stationary or trailer-mounted pumps, these pumps are
connected to flexible hoses or rigid pipes to transport concrete to the desired
location.

 Specialty Pumps: Include specialized equipment like skid-mounted or rail-

mounted pumps used for specific applications.
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b. Components of a Concrete Pump

 Pump Unit: The core component that generates the pumping pressure.
 Hopper: Receives the concrete from the mixer and feeds it into the pump.
 Valve System: Directs the concrete flow from the hopper into the pipeline.
 Pipes and Hoses: Transport the concrete from the pump to the placement site.
 Boom (for Boom Pumps): A hydraulically operated arm that delivers concrete
to high or hard-to-reach areas.

2. Concrete Mix Design for Pumping

a. Workability
 Slump: Optimal slump for pumped concrete typically ranges from 75 to 125
mm (3 to 5 inches) to ensure smooth flow.
 Consistency: The concrete should have a cohesive and non-segregating mix.
b. Aggregate Size and Grading
 Maximum Aggregate Size: Should be less than one-third of the smallest pipe
diameter, typically not exceeding 20 mm.
 Grading: Well-graded aggregates help in achieving a pumpable mix.
c. Water-Cement Ratio
 Ideal Range: Generally between 0.4 and 0.6. A higher water-cement ratio can
improve pumpability but may affect strength and durability.
d. Admixtures
 Plasticizers: Improve the workability without increasing water content.
 Air-Entraining Agents: Improve workability and reduce the risk of
segregation and bleeding.
 VMA (Viscosity Modifying Admixtures): Enhance the cohesiveness of the
mix.
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3. Preparation and Setup
a. Site Preparation
 Accessibility: Ensure the pump can be positioned close to the pouring area with
clear access for the delivery trucks.
 Safety Measures: Establish safety protocols around the pump and pipeline to
prevent accidents.
b. Equipment Setup
 Pipelines: Ensure that pipelines are clean, leak-free, and securely connected.
 Lubrication: Prime the pump and pipelines with a slurry mix (cement and
water) to lubricate and prevent blockages.
4. Pumping Process
a. Initial Pumping
 Priming: Start by pumping the slurry mix to coat the inside of the pipes.
 First Batch: Gradually introduce the concrete mix into the hopper.
b. Continuous Pumping
 Flow Control: Monitor and control the flow rate to avoid segregation and
maintain a consistent flow.
 Pressure Monitoring: Regularly check the pressure gauges to detect any
blockages or issues.
c. Placement Techniques
 Placement Sequence: Plan the sequence of concrete placement to minimize
delays and cold joints.
 Operator Coordination: Maintain communication between the pump operator
and placement crew to ensure proper distribution.
5. Troubleshooting Common Issues
a. Blockages
 Prevention: Use well-graded aggregates and an appropriate mix design.
 Resolution: Reverse the pump briefly to relieve pressure and clear the blockage.
b. Segregation
 Cause: Often due to high slump or excessive water content.
 Solution: Adjust the mix design and ensure proper admixture use.
c. Bleeding
 Cause: Excessive water in the mix.
 Solution: Use proper water-cement ratio and incorporate air-entraining agents.
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6. Cleaning and Maintenance
a. Cleaning After Use
 Pipes and Hoses: Clean thoroughly after each use to prevent concrete from
hardening inside.
 Pump Unit: Flush with water and clean the hopper, valves, and other
components.
b. Regular Maintenance
 Inspection: Regularly inspect the pump and pipeline for wear and damage.
 Lubrication: Keep moving parts well-lubricated to ensure smooth operation.
7. Safety Considerations
a. Personal Protective Equipment (PPE)
 PPE for Workers: Hard hats, gloves, safety glasses, and steel-toed boots.
b. Operational Safety
 Safe Distance: Maintain a safe distance from the pump and pipeline during
operation.
 Emergency Procedures: Have clear procedures in place for handling
emergencies such as blockages or equipment failure.
8. Advantages of Concrete Pumping
 Efficiency: Faster placement of concrete compared to traditional methods.
 Accessibility: Ability to place concrete in hard-to-reach or elevated areas.
 Quality: Consistent and uniform placement, reducing the risk of segregation
and cold joints.
 Labor Savings: Reduced labor requirements and increased productivity.
9. Applications of Concrete Pumping
 High-Rise Buildings: Efficiently pump concrete to upper floors.
 Bridges and Tunnels: Reach difficult and confined spaces.
 Large Slabs and Foundations: Quickly place large volumes of concrete.
 Infrastructure Projects: Use in roads, dams, and other large-scale
constructions.

 PUMPING OF CONCRETE WITH BOOM PACER

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Boom pumps, also known as boom placers, are advanced pieces of equipment used
for pumping and placing concrete. These pumps are truck-mounted and equipped with
a hydraulic arm (boom) that can be remotely controlled to deliver concrete to precise
locations. This method is particularly effective for high-rise buildings, large
infrastructure projects, and areas with difficult access.

1. Equipment Overview
a. Components of a Boom Pump
 Truck Chassis: Provides mobility and a stable base for the pump and boom.
 Pump Unit: Generates the pressure required to move concrete through the pipeline.
 Hopper: Receives concrete from the mixer and feeds it into the pump.
 Boom: A hydraulically operated arm with multiple sections that can be extended
and articulated.
 Pipeline: Carries concrete from the hopper, through the boom, and to the placement
point.
 Remote Control: Allows the operator to control the boom's movements and
concrete flow.
2. Preparation and Setup
a. Site Preparation
 Access: Ensure that the truck has clear and stable access to the pumping site.
 Stability: Position the truck on a firm, level surface to prevent tipping.
 Safety Measures: Set up barriers and signage to keep personnel away from the
pump and boom operating area.
b. Equipment Setup
 Boom Placement: Position the boom to cover the area where concrete will be
placed. Consider obstacles such as overhead wires and structures.
 Pipeline Connections: Securely connect the pipeline sections and check for leaks.
 Priming: Prime the pump and pipeline with a slurry mix to lubricate the system and
prevent blockages.
3. Concrete Mix Design for Pumping
a. Workability
 Slump: The ideal slump for pumped concrete is typically between 75 to 125 mm (3
to 5 inches).
 Consistency: Ensure the mix is cohesive and non-segregating.
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b. Aggregate Size and Grading
 Maximum Aggregate Size: Should be less than one-third of the smallest pipe
diameter, usually not exceeding 20 mm.
 Grading: Use well-graded aggregates to enhance pumpability.
c. Water-Cement Ratio
 Range: Typically between 0.4 and 0.6 to balance workability and strength.
d. Admixtures
 Plasticizers: Improve workability without adding water.
 Air-Entraining Agents: Enhance workability and reduce segregation.
 Viscosity Modifying Admixtures (VMA): Improve mix cohesiveness.
4. Pumping Process
a. Initial Pumping
 Priming the System: Pump a slurry mix through the system to coat the pipes.
 Starting the Flow: Gradually introduce the concrete mix into the hopper.
b. Continuous Pumping
 Flow Rate Control: Adjust the pump speed to maintain a consistent flow and
prevent segregation.
 Pressure Monitoring: Continuously monitor pressure gauges to detect and
address any blockages.
c. Boom Operation
 Boom Movement: Use the remote control to precisely position the boom over
the placement area.
 Safety: Avoid sudden movements and ensure the boom is clear of obstacles and
personnel.
5. Placement Techniques
a. Placement Sequence
 Strategic Planning: Plan the placement sequence to minimize delays and cold
joints.
 Coordination: Maintain communication between the pump operator and
placement crew to ensure even distribution.
b. Layering and Compaction
 Layer Placement: Place concrete in layers to avoid segregation and ensure
proper compaction.
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 Vibration: Use vibrators to compact concrete and remove air pockets,
especially in deep sections.
6. Troubleshooting Common Issues
a. Blockages
 Prevention: Use a pumpable mix design with well-graded aggregates.
 Clearing: Reverse the pump briefly to relieve pressure and clear blockages.
b. Segregation
 Cause: High slump or excessive water content.
 Solution: Adjust the mix design and use appropriate admixtures.
c. Bleeding
 Cause: Excessive water content.
 Solution: Maintain an optimal water-cement ratio and use air-entraining agents.
7. Cleaning and Maintenance
a. Cleaning After Use
 Pipelines and Hoses: Clean thoroughly after each use to prevent concrete from
hardening inside.
 Pump Unit: Flush with water and clean the hopper, valves, and other
components.
b. Regular Maintenance
 Inspection: Regularly inspect the pump and boom for wear and damage.
 Lubrication: Keep moving parts well-lubricated to ensure smooth operation.
8. Safety Considerations
a. Personal Protective Equipment (PPE)
 PPE for Workers: Hard hats, gloves, safety glasses, and steel-toed boots.
b. Operational Safety
 Safe Distance: Maintain a safe distance from the pump and boom during
operation.
 Emergency Procedures: Have clear procedures for handling emergencies such
as blockages or equipment failure.
c. Boom Safety
 Stability: Ensure the truck is stable and the boom is properly balanced.
 Clearances: Avoid overhead obstructions and ensure safe operation within the
boom’s reach.
9. Advantages of Boom Pumps
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 Efficiency: Faster and more precise concrete placement compared to traditional
methods.
 Accessibility: Ability to place concrete in hard-to-reach areas and at heights.
 Quality: Consistent and uniform placement, reducing the risk of segregation
and cold joints.
 Labor Savings: Reduced labor requirements and increased productivity.
10. Applications of Boom Pumps
 High-Rise Buildings: Efficiently pump concrete to upper floors.
 Bridges and Tunnels: Reach difficult and confined spaces.
 Large Slabs and Foundations: Quickly place large volumes of concrete.
 Infrastructure Projects: Use in roads, dams, and other large-scale
constructions.

 LEVELLING OF CONCRETE
Levelling concrete is a critical step in many construction projects, ensuring that surfaces
are even and smooth for structural integrity and aesthetic purposes.
1. Preparation
a. Site Preparation
 Clear the Area: Remove all debris, vegetation, and topsoil.

 Compact the Subgrade: Use a plate compactor or roller to compact the soil. This
prevents settling.
 Install Forms: Set up wooden or metal forms to contain the concrete. Ensure they
are level and secure.
b. Materials and Tools
 Concrete Mix: Choose the right mix for your project (e.g., standard, high-strength,

or fast-setting).
 Tools: Shovels, rakes, screeds, bull floats, trowels, and edgers.
2. Pouring the Concrete
a. Mixing
 Batching: Measure the correct proportions of cement, sand, gravel, and water.
 Mixing: Use a concrete mixer to combine the materials until the mixture is uniform.
b. Pouring
 Distribution: Pour the concrete within the forms evenly.
 Consolidation: Use a vibrator or tamping rod to eliminate air pockets and ensure
even distribution.
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3. Levelling Techniques
a. Screeding
 Straight Edge: Use a long, straight screed board or aluminum screed.
 Motion: Move the screed back and forth across the surface while pulling it
along the forms. This removes excess concrete and levels the surface.
b. Floating
 Bull Float: After screeding, use a bull float to further level the surface and push

down aggregate.
 Timing: Start when the concrete is still wet but has begun to stiffen.

4. Finishing
a. Troweling
 Initial Trowel: Use a steel trowel for the first pass to smooth the surface.
 Final Trowel: Once the concrete has firmed up a bit more, trowel again for a
smooth finish.
b. Edging and Jointing
 Edging: Use an edging tool to smooth the edges of the slab.

 Jointing: Create control joints with a groover to prevent cracking.

5. Troubleshooting Common Issues
a. Uneven Surface
 Causes: Poor screeding, inadequate floating, or uneven subgrade.

 Solutions: Re-screed while wet, grind down high spots, or fill low spots with a thin
overlay.
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b. Cracking
 Causes: Rapid drying, lack of control joints, or poor subgrade preparation.

 Solutions: Ensure proper curing, install control joints, and prepare the subgrade
correctly.
7. Safety Considerations
 Protective Gear: Wear gloves, safety glasses, and boots.
 Handling Concrete: Wet concrete can cause skin irritation. Wash off any
concrete that comes into contact with the skin.
 Lifting: Concrete is heavy; use proper lifting techniques to avoid injury.

 VIBRATION AND COMPACTION OF CONCRETE

Vibration and compaction of concrete are crucial processes that ensure the concrete
achieves its maximum strength and durability by eliminating air pockets and achieving
a uniform, dense structure.

1. Introduction to Vibration and Compaction

 Purpose: The primary goal is to remove entrapped air and reduce voids within
the concrete mix, thus increasing its density and strength.
 Methods: Vibration (internal, external) and compaction (manual, mechanical).

2. Vibration Techniques
a. Internal Vibration
 Equipment: Internal vibrators, also known as immersion or poker vibrators.
 Procedure:
o Insertion: Insert the vibrator vertically into the concrete at regular intervals
(typically about 30-50 cm apart).
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o Duration: Vibrate for 5-15 seconds at each spot or until no more air bubbles
appear on the surface.
o Overlap: Ensure overlapping of vibration zones to avoid untreated areas.
o Withdrawal: Withdraw slowly to avoid leaving voids.

b. External Vibration
 Equipment: Form vibrators, surface vibrators, or vibrating tables.
 Procedure:
o Form Vibrators: Attach to the exterior of the formwork. Useful for thin
sections or heavily reinforced areas.
o Surface Vibrators: Used on the surface of slabs and pavements.
o Vibrating Tables: Used in precast concrete production.
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3. Compaction Techniques
a. Manual Compaction

 Tools: Hand tools like tampers, rods, or spades.

 Procedure:
o Layering: Place concrete in layers of 15-20 cm.
o Tamping: Use a tamper to compact each layer.
o Rodding: Insert a rod or spade into the concrete repeatedly to release trapped
air.

b. Mechanical Compaction
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 Equipment: Compactors, roller screeds.
 Procedure:
o Roller Screeds: Used for slabs; combine screeding and compaction.
o Plate Compactors: Useful for compacting sub-bases and initial concrete
layers.

4. Key Factors in Effective Vibration and Compaction

a. Concrete Mix Design

 Workability: Ensure the concrete mix has adequate workability for easy
compaction.
 Aggregate Size: Properly graded aggregates to minimize voids.

b. Timing

 Initial Setting: Begin vibration and compaction immediately after placing the
concrete.
 Workable Window: Complete the process before the concrete starts to set.

5. Common Issues and Troubleshooting

a. Over-Vibration

 Symptoms: Segregation of the mix, excessive bleeding.

 Prevention: Limit vibration duration; adjust the frequency and amplitude.

b. Under-Vibration
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 Symptoms: Honeycombing, air voids, weak spots.
 Prevention: Ensure adequate vibration time and coverage.

c. Improper Use of Equipment

 Symptoms: Inefficient compaction, equipment damage.
 Prevention: Train operators properly; maintain equipment regularly.

6. Safety Considerations
 Protective Gear: Wear gloves, safety glasses, and ear protection.
 Handling Vibrators: Ensure secure handling to avoid accidents.
 Electric Equipment: Check for electrical hazards, ensure proper grounding.

7. Quality Control
 Visual Inspection: Look for signs of adequate compaction (uniform surface, no
honeycombing).
 Testing: Conduct slump tests, compressive strength tests, and core samples.
 Documentation: Keep records of equipment used, procedures followed, and
results obtained.

 Finishing and Curing of Concrete

Finishing and curing are crucial processes in concrete construction that
significantly affect the surface quality, durability, and strength of the finished product.

1. Finishing Concrete
Finishing involves the final steps to smooth and texture the surface of the concrete to
meet the project's specifications.

a. Initial Steps

1. Screeding

 Purpose: Remove excess concrete and bring the surface to the proper grade.
 Tool: Straightedge or screed board.
 Procedure: Drag the screed across the forms using a sawing motion to level the
surface.
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2. Bull Floating

 Purpose: Embed aggregate particles below the surface and remove high and
low spots.
 Tool: Bull float.
 Procedure: Push and pull the bull float across the surface, keeping the leading
edge slightly elevated to avoid digging into the concrete.

b. Intermediate Steps

3. Edging

 Purpose: Create rounded edges to prevent chipping.

 Tool: Edger.
 Procedure: Run the edger along the edges of the concrete.

4. Jointing

 Purpose: Create control joints to manage cracking.

 Tool: Groover.
 Procedure: Press the groover into the concrete at specified intervals, usually
about every 10 feet for a 4-inch slab.

5. Floating

 Purpose: Further smooth the surface and compact the concrete.

 Tool: Magnesium or wooden float.
 Procedure: Float the surface using sweeping motions to achieve a more refined
finish.

c. Final Steps

6. Troweling

 Purpose: Achieve a smooth, hard surface.

 Tool: Steel trowel or power trowel.
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 Procedure: Perform initial troweling when the concrete is firm enough to
withstand some pressure but still plastic. Perform subsequent trowelings as the
surface hardens.

7. Texturing

 Purpose: Provide a non-slip surface, if required.

 Tool: Broom, trowel, or roller.
 Procedure: Apply the desired texture before the concrete fully hardens.

 Curing Concrete
Curing involves maintaining adequate moisture, temperature, and time to allow the
concrete to achieve its intended strength and durability.

a. Methods of Curing
1. Water Curing

 Purpose: Keep the concrete surface continuously wet.

 Techniques:
o Ponding: Create ponds of water on flat surfaces.

o Sprinkling: Apply a continuous spray or mist of water.

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o Wet Coverings: Use wet burlap, cotton mats, or sand.

2. Sealing
 Purpose: Prevent moisture loss.
 Materials: Plastic sheeting, waterproof paper, or curing compounds.
 Procedure: Apply covering or curing compound after the concrete surface is
firm.

3. Steam Curing
 Purpose: Accelerate strength gain, often used in precast concrete.
 Procedure: Expose the concrete to steam under controlled temperature and
humidity.
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b. Timing
1. Initial Curing (Bleed Water Removal)
 Purpose: Allow bleed water to evaporate.
 Timing: Typically starts immediately after finishing and lasts until the concrete
surface starts to lose its sheen.

2. Intermediate Curing
 Purpose: Maintain moisture content and prevent surface drying.
 Timing: From the end of initial curing to the beginning of final curing.

3. Final Curing
 Purpose: Ensure complete hydration and strength development.
 Timing: Typically lasts for a minimum of 7 days, with 28 days for full curing
in most cases.

3. Key Factors Affecting Finishing and Curing

a. Environmental Conditions
 Temperature: High temperatures accelerate setting and require faster finishing
and more intensive curing. Low temperatures slow setting and require extended
curing periods.
 Wind: High winds increase evaporation rates, necessitating more rigorous
curing to prevent cracking.
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 Humidity: Low humidity increases the risk of rapid drying and cracking,
requiring additional moisture.

b. Concrete Mix
 Water-Cement Ratio: Affects workability and drying time.
 Admixtures: Accelerators, retarders, and plasticizers impact setting time and
workability.
 Aggregate Size and Type: Influence surface finish quality.

c. Project Specifications
 Surface Requirements: Smooth, textured, or patterned finishes.
 Structural Requirements: Strength and durability considerations.

4. Common Issues and Solutions

a. Finishing Issues
 Crusting: When the surface dries too quickly, causing difficulties in finishing.
Solution: Delay finishing or use evaporation retardants.
 Blisters: Air trapped under the surface during troweling. Solution: Adjust
troweling timing and technique.
 Dusting: Weak, powdery surface due to over-troweling or poor curing.
Solution: Use proper curing methods and avoid excess water in the mix.

b. Curing Issues
 Plastic Shrinkage Cracking: Rapid moisture loss from the surface. Solution:
Use windbreaks, shade, or fog sprays.
 Crazing: Fine surface cracks due to rapid drying. Solution: Ensure proper
curing and avoid overworking the surface.
 Curling: Warping of slabs due to differential moisture loss. Solution: Maintain
uniform moisture and temperature conditions during curing.

5. Safety Considerations
 Protective Gear: Wear gloves, safety glasses, and proper footwear.
 Handling Chemicals: Follow safety guidelines for handling curing compounds
and sealants.
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 Ergonomics: Use proper lifting techniques and tools to reduce physical strain
during finishing.

6. Quality Control
 Surface Inspection: Check for uniformity, texture, and absence of defects.
 Strength Testing: Perform compressive strength tests on cured concrete
samples.
 Documentation: Keep records of curing conditions, methods used, and any
issues encountered.
 Module 4

MIXING OFCONCRETE
The aim of mixing of concrete is to produce a homogenous, consistent and
uniform coloured concrete.
This means that the different constituents
of concrete be uniformly distributed throughout the concrete mass and the
cement-water paste should completely coat the aggregates.

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.
II. A vigorous rubbing action of cement paste on to the surface of the
aggregate particles
There are two methods of mixing concrete:
(1)Hand mixing
(2) Machine mixing

1. HAND MIXING
 Mixing concrete by hand is hard work. While you can mix the
ingredients in a wheelbarrow.
 it's usually easier to mix them on a clean, flat surface, such as an old
sheet of plywood, or in a mortar box (also called a concrete barge).
 When mixing concrete by any method, make sure to protect yourself by
wearing long sleeves, long pants, rubber boots, heavy waterproof
gloves, and safety goggles.
 If concrete accidentally spatters on your skin, wash it off immediately
because it causes burning irritation.
.
The following operations are involved in hand mixing.
1. Test the water content of the sand. The sand used to make the concrete should be wet, but
not too wet.
2. sand with the correct amount of water will hold a ball shape without wetting your hand,
very wet sand will make a ball but "leak" water, while dry sand will crumble and not hold
a shape.
3. If the sand is too dry, wet it thoroughly using a garden hose the day before beginning
work.
4. Always scover your sand pile with a sheet of plastic when you're not working, to prevent
the sand from drying out.
Measure the ingredients.
 For mixing purposes, you can measure proportions by the bucket or
with a measuring box, like the one shown in figure. A measuring box is
built to hold exactly 1 cubic foot of dry ingredients.
 Careful measuring ensures correct proportions. Place the materials in
layers on top of each other, beginning with the gravel, then the sand, and
finally the cement.
Mix the dry ingredients.
 If you're working on a flat surface or mixing the
ingredients in a wheelbarrow, use a mason's hoe to combine the dry
ingredients thoroughly before adding the water.
 When using a mortar box, you can either premix the dry ingredients or mix
them together as you add the water as shown in the figure.
 If you're mixing on a flat surface, make a shallow depression in the centrebof the dry mix
using your hoe; then pour in a little water (Fig.). Add the water slowly. Mix thoroughly by
pulling dry material from the edges into the water.
 Continue to add water until the mix reaches the proper consistency not crumbly, not sloppy.
If using a mortar box, place the dry materials so that they fill about two-thirds of the box
(from one end), leaving the rest of the box empty (on the side nearest the forms).
 Add water to the empty end, and then pull the dry materials into the water, mixing them
together as you go.
 Continue adding water in small amounts while turning over the mix untilit reaches the
proper consistency
 MACHINE MIXING
Machine mixing is adopted for big projects where large quantities of concrete are required
are continuously. Machine mixing is not only efficient, but also economical, when the
quantity of concrete to be produced is large
Concrete mixers are classified as under:
1. According to the operating conditions:
i. Batch mixers
ii. Continuous mixers.
2. According to the principle of mixing:
i. Gravity type
ii. Type with forced mixing.
3. According to the condition of use:
i. Stationary concrete mixers
ii. Portable concrete mixers.
1. Batch Mixer
 In this case, the mixers are charged with materials in batches. Each new
batch will be charged in to the drum of the mixer only when the preceding
batch has been discharged.
 Batch mixers are used for normal concrete works.
 They produce concrete batch by batch with time interval
 Batch mixers can be classified in to three main types. They are,
a) Tilting type
b) Non-tilting type
c) Reversing type
As per IS: 1971-1985,
concrete mixers are designated by a number representing its nominal
mixed batch capacity in litres. The following are the standardized sizes of
three types:
i. Tilting type : 85 T, 100 T, 140 T, 200 T
ii. Non-tilting type: 200 NT, 280 NT, 375 NT, 500 NT, 1000 NT
iii. Reversing type: 200 R, 280 R, 375 R, 500 R, 1000 R
The letters T denote tilting type, NT denote non-tilting type and R denote reversing type
 The non-tilting type mixture essentially consists of a cylindrical drum with two circular
openings at the ends and blades fixed inside the drum.
 The drum rotates about a horizontal cannot be tilted.
 The mixer is loaded through a central opening at one end of
drum and, after mixing, the concrete is discharged through the opening at the other end
by a chute.
 Owing to a rather slow rate of discharge, the concrete is sometimes susceptible to
segregation.
 In particular, the Iarger size aggregate may tend to stay in the mixer.
 Reversible concrete mixer, Reversible Drum Mixer are strong well-engineered piece of
construction equipment which is meant for carrying mixing mortar from batch
plant directly to the place where it is to be poured.
 It has a wide range of applications specially used in construction of canals, bridges,
highways, dams, multistoried & industrial buildings,
factories and for ready mixed concrete works.
The second category of mixers is continuous mixers.
As the name indicates, the materials are continuously fed into the mixer at the same rate
as the concrete is discharged.
They are usually non-tilting drums with screw-type blades rotating in the middle of the
drum.
The drum is tilted downward toward the discharge opening. The mixing time is
determined by the slope of the drum(usually about 15 degree).
STATIONARY CONCRETE MIXTURES
 A concrete mixing plant is a huge set up of machines meant to combine cement,
aggregates such as sand or gravel, and water to form concrete.
 Concrete mixing plants apart from various other equipment’s also uses a revolving
drum to mix the components.
 Concrete mixers may be mobile or stationary. Its size range from portable mixer to
heavy industrial mixing plant.
 PORTABLE TYPE CONCRETE MIXTURE

The name says it all. Portable cement mixer can be transported from one site to another with
ease.
Making it the most commercialized concrete mixer out there. That also means that they are
the most cement mixers been abused and over worked.
One of the main advantages of this type of concrete mixer is that you don’t need to add extra
water for the mixing process.
This is the type of cement mixers that you would use for a typical house project.
The rotation of the concrete mixture is powered by means of electricity.
The lever allows the concrete/mortar to be tipped in to a wheelbarrow.
TRANSPORTATION OF CONCRETE
• Defined as the transferring of concrete from the mixing plant to the
construction site.
• The main objective in transporting concrete is to ensure that the water-
cement ratio, slump or consistency, air content, and homogeneity are not
modified from their intended states.
• Transportation of concrete is an important activity in the production of
concrete.
• The time taken in transit should be a design parameter as it depends on
the initial setting time as well as the requirement of workability at the
destination.
• The method of transportation adopted at site should be decided in
advance so that suitable admixtures can be decided.
• The successful placement of concrete is dependent upon careful mixing,
the proper equipment, and adequate transportation.
• After mixing, concrete shall be transported to the formwork as soon as
possible by methods which will prevent the segregation or loss of any of
the ingredients or water and maintaining the required workability.
• During hot or cold weather concrete shall be transported in deep
containers. Other suitable methods to reduce the loss of water by
evaporation in hot weather and heat loss in cold weather may also be
adopted.
 IMPORTANT FACTORS IN TRANSPORTING CONCRETE

• The two key goals when transporting concrete from the mixing plant to
the construction site are to prevent segregation and to not reduce the
workability of the mix.
• This transportation process must be well thought out and organized
efficiently.
• As a general rule of thumb, thirty to sixty minutes of transportation are
acceptable on small jobs. At a central or portable ready-mix plant,
concrete should be discharged from a truck mixer or agitator truck within
two hours.
VARIOUS METHODS OF TRANSPORTATION OF CONCRETE
1. MORTAR PAN
It is a labour intensive method and generally used for small works.
There are no chances of segregation of concrete.
In hot weather, there is a substantial loss of water due to more exposure of
concrete to environment.
2. WHEEL BARROW OR HAND CART
• It is normally used on ground level i.e. road construction and other similar
structures.
• Segregation can occur if transportation is done on rough roads, however this
problem can be minimizes if pneumatic tyres are used
3. BUCKET AND ROPEWAY
It is suitable for works in valley, over high piers and long dam sites. Excessive
free fall of concrete should be avoided to minimize segregation.
4. TRUCK MIXER AND DUMPER
• It is an improved and better method for long lead concreting. The concrete is
covered with tarpaulin if it is transported in open trucks. If long distance is
involved, agitators should be used.
5. BELT CONVEYOR
• It has limited application due to chances of segregation on steep slopes,
roller points and changes in direction of belt. It also involves over-exposure
of concrete to environment
6. PUMP AND PIPE-LINE METHOD
• It is the most sophisticated method particularly suitable for limited space or
when a large quantity of concrete is to be poured without cold joints.
• Pumping of concrete can be done @ 8 to 70 cubic meters per hour up to a
horizontal distance of 300 meter and vertical distance of 90 meter.
• Pipe dia is generally 8 to 20cm and it is made of steel, plastic or aluminium.
• The workability for pumped concrete should have a minimum of 40 to 100
mm of slump or 0.90 to 0.95 compacting factor.
• At delivery point the workability may be reduced by 25% due to compaction
and this factor should be kept in mind while designing the mix.
7. TRANSIT MIXER
• Transit mixer is one of the most popular equipment for transporting
concrete over a long distance particularly in ready mix concrete plant.
• They are truck mounted having a capacity of 4 to 7 cubic meter.
• There are two variations. In one, mixed concrete is transported to the site
by keeping it agitated all along at a speed varying between 2 to 6
revolutions per minute.
• In 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 concrete at site.
 Ready-mix concrete
• There are two options regarding use of concrete i.e. site mixed concrete or ready
mixed concrete.
• Site mixed concrete is prepared at construction site, whereas Ready Mixed Concrete
is prepared at Central Batching and Mixing Plant and transported to construction
site.
• Site mixed concrete is more preferred in our country.
• Ready Mixed Concrete is widely adopted in developed countries.
• The reasons for popularity of Ready Mixed Concrete(RMC) are assured good
quality, as RMC is produced under controlled conditions and its readily availability.
• The general requirement is that concrete shall be discharged from the truck-mixer
within 2h of the time loading. However, a longer period may be permitted if
retarding admixtures are used or in cool humid weather or when chilled concrete is
produced.
• The time of loading shall start from adding the mixing water to the dry mix of
cement and aggregate or of adding the cement to the wet aggregate whichever
is applicable.
• Ready-mixed concrete plant shall have test facilities at its premises to carry
out routine tests as per the requirement of the standard.