CHAPTER 5

ORGANISATION OF CONCRETE WORKS

5.1. Introduction

Concreting involves a chain of events: mixing, transporting and placing. The main purpose here is to establish
the time available for pouring a given quantity of concrete by deducting the time consumed for mixing and
transporting from the total amount of time (until the concrete starts setting). Then, within the remained time, the
proper concreting gang size is to be determined. The calculation initially refers to that quantity of concrete
which is transported with a hauling unit (lorry, ready-mix truck a.s.o.); (Eq. 5.1).
to = tmix + tTR + tpl ;<hours> (5.1)

where:
to = Total time available - depends on the type of cement, temperature and
admixtures (if used) (given by standards);
tmix = Time needed for mixing - depends on the type of batching and mixing
plant;
tTR = Transporting time - depends on the distance between the mixing plant
and the site, speed of the vehicle, type of road etc.;
tpl = Time needed for placing - depends on the concrete gang size or the type
of equipment used for pouring the concrete; type of element to be poured
etc.
tpl = to - tmix - tTR (5.2)

If tpl resulted from the first trial is too small, it can be made acceptable by either increasing t o (by using
retarders) or by decreasing tmix and/or tTR (by using ready mix trucks, selecting a better road where the speed
can be increased, find another concrete supplier placed closer to the site a.s.o.).
Some of the most spreaded situations will be presented below.

5.2. Manual mixing, transporting and placing of concrete.

The case studied below refers to the manual mixing, transporting by wheel-barrows and manual placing. This
solution is suitable in case of small quantities of concrete - less then 10 m 3 - and remote locations. The
calculation will follow the steps presented below :

(i) Establish the time needed for manual mixing of concrete (Eq. 5.3)
q N
t mix c Tmix ;< hours > (5.3)
M mix
Mmix = gmmix (5.4)

where:
qc = quantity of concrete in a batch (m3)
g = 1,2,3...
(ii) Establish the remained time for placing the concrete (Eq. 5.5)
tpl t omax - t mix ;< hours > (5.5)

If t pl results too small, or smaller than zero, then t mix should be reduced either by increasing the gang size
and/or by decreasing the quantity of concrete to be manufactured. In this case it is unusual to use retarders, but
sometimes this measure can be adopted too.
(iii) Establish the gang size for placing the concrete within the remained time (M pl).(Eq.5.6 and 5.8).

Concrete placing involves both transporting the concrete with wheel barrows and placing it.

M pl

q c N TRB
T
pl
c NT ;< men > (5.6)
t pl

where:
Mpl = gang responsible with placing;
men h
N TRB
T = labour performance rate for transporting with wheel barrows < t >;
men h
N Tpl = labour performance rate for placing; < >;
m3
c = density of concrete; < t/m3 >.

The optimum size of the gang should contain operatives for transporting and for pouring.
mpl = mTR + mpo ;< men > (5.7)

where :
mTR = optimum gang size for transporting;
mpl = optimum gang size for pouring.

Then the actual gang size should be:

M apl M pl so that M apl g m pl (5.8)

M apl being greater than M pl than the actual time for placing the concrete must be re-adjusted:

t apl

q c N TRB
T
pl
c NT ;< hours > (5.9)
M apl

(iv) Establish the total duration of the process (Eq.5.10)

t t amix t apl ;< hours > (5.10)

where:
t amix = time needed to mix the first batch;
(v) Establish the total quantity of concrete which can be manufactured and placed in a working day (in a shift
duration): (Eq.5.11/5.12)
ds
q cs,mix q c ;< m3/day > (5.11)
t mix
d
q cs,pl q c as ; < m3/day > (5.12)
t pl
 If qcs,pl is sensibly different of qcs,mix , it means that the two gangs have different outputs and either one gang or
the other will have a poor work load.

If qcs,mix > qcs,pl this means that in a working day it would be possible to mix a quantity of concrete greater
than the actual quantity which could be placed. Consequently, the actual quantity of concrete to be mixed
being equal to that quantity to be placed, the mixing gang has a poor work load.
If qcs,mix < qcs,pl following the same deductions as above, results that the gang responsible with concrete
placing has a poor workload.

In both cases, further trials should be undertaken to balance those two phases of the process (manufacturing and
placing) and consequently to improve the work load of two gangs.

5.3. Ready-mix concrete, truck hauling, and pumping

(i) Establish the time needed for mixing a quantity of concrete equal to the capacity of the truck mixer
M c
t mix q Tc N TU ;< hours > (5.13)
c

where:
qT 3
c = the quality of concrete to be mixed for a transport, equals to the capacity of the truck mixer < m >;
M
N TU = the concrete plant performance rate < hours/m 3 of concrete placed and compacted >;
c = the density of concrete before compaction. Assume c = 2.2 t/m3
c = the density of concrete after compaction. Assume c = 2.4 t/m3
(ii) Establish the other items of time consumed before placing the concrete
tml = time to manoeuvre the truck for loading = (12) min
tD = time for transporting to site;
D
tD (5.14)
S
where:
D = distance between concrete plant and site <km>
S = average speed <km/h>

tmd = time to manoeuvre for discharging the concrete (12) min.

(iii) Establish the remained time for placing the concrete (Eq.5.15)
t av max
pl t o ( t ml t mix t D t md ) ;< hours > (5.15)

(iv) Establish the time needed for a concrete pump to place the concrete delivered with a truck mixer
(Eq.5.16).
In this case, the concrete pump is the dominant item of the process, regardless the number of operatives
designated to handle the concrete (m pl) and to assist the discharging of the concrete (m des). The rate of
progress must be determined considering the process as being mechanised (Eq. 5.16).
P b
t apl t p q Tc N TU ;< hours > (5.16)
b
where:
 P
N TU = the concrete pumping performance rate; < hours/m 3 compacted concrete>
M
tp = the specific pumping time for a q b quantity of concrete.

(v) Compare t av
pl with t
p

If t av p
pl < t => the time available to pump and consequently to pour the concrete is not sufficient.
Hence the available time should be increased in various ways until it becomes at least equal to t p:
using retarders;
increasing the average speed;
finding another supplier closer to the site (decreasing the distance D).
If t av p
pl > t => the work can be performed.

(vi) Determine the gang size

Because the operatives do not have a dominant role, in that a greater number than the optimum gang size will
not reduce the time for placing the concrete, the gang size will be determined as follows (Eq. 5.17):
Mef = mpl + mdis (5.17)

(vii) Establish the quantity of concrete which can be placed in a one shift working day (Eq. 5.18)
M ds
q cs q Tc

a ;< m3 > (5.18)
t pl t md

(viii) Establish the number of days to place a "Q" quantity of concrete.

Q
T M 1 ;< days > (5.19)
q CS
or
P
Q N TU (5.20)
T ;Ta T; < days >
d s U K PFU

(ix) Establish the required number of concrete transports per day

d
n nec as ;< transports > (5.21)
t pl

(x) Establish the maximum number of transports per day, possible for a truck mixer.
d
n pos s K M T
FU K FU ;< transports > (5.22)
TT
where:
TT = duration of a transporting cycle
TT = tml + tl + 2tD + tmd + tpl ;< hours >

tl = tmix. The truck waits to be loaded as the plant mixer manufactures the concrete.

(xi) Establish the necessary hauling units per day

 n
N T nec 1 ;< trucks > (5.24)
n pos

II. Pumping
8. 2B02 Concrete pumping in foundations m3 4
(simple concrete)
a. strip footings 0.156 0.03
b. pad foundation 0.172 9
0.04
3
9. 2B05 Idem reinforced concrete m3 4
c. strip footings 0.164 0.04
d. pad foundation 0.180 1
0.04
5
10. 2B07 Idem in reinforced raft foundations m3 4 0.288 0.07
(A.P.B. 50) 2
11. 2B08 Idem in pad foundations for m3 4 0.276 0.06
precast columns (A.P.B. 50) 9
12. 2B10 Idem in foundation, concrete being m3 3 0.60 -
discharged directly form ready-
mix trucks
13. 2B12 Concrete pumping in columns m3 4 0.102 0.07
(A.P.B. 50)
14. 2B16 Idem in walls (A.P.B. 50) m3 4 0.332 0.08
3
15. 2B18 Idem in water reservoirs etc. m3 4 0.360 0.09
0
16. 2B20 Idem in slabs (including beams m3 4 0.312 0.07
and girdles) or in overconcreting 8
17. 2B28 Pump positioning 1 station 2 0.26 0.13
18. 2B29 Pump priming 1 prim 2 1.05 -
19. 2B32 Discharge concrete form ready- m3 1 0.20 -
mix truck into skips

Table 5.5. Transport of concrete and other materials with wheelbarrows and cranes
No. Code Description of process UM. m. NT NTU
1. 21A1 Transport with wheelbarrows t 1
a. for 10 m 0.500.7 -
b. for each 10 m over the first 10 m 1 -
0.098
2. 21A6 Materials transport by direct carrying t 1 0.711.4 -
(10m) 0.260.5 -
surplus for each 10 m over the first 9
10 m
3 22E3 Transport with tower cranes MT 40; t 2
MT 100.
a. MT 40
Weight 0.50 t 0.240.6 -
Height (m) : 13 m 5 -
1325 m 0.320.8 -
2542 m 1
Weight = (0.50-1.00) t 0.371.0 -
Height (m) : 13 m 5 -
1325 m -
2542 m 0.110.1
Weight = (1.00-2.00) t 9 -
Height (m) : 13 m 0.150.2 -
1325 m 4 -
2542 m 0.190.3
3

0.060.1
1
0.080.1
4
0.100.1
8
. a. MT 100 t
Weight 0.50 t
Height (m) : 13 m 0.320.8 -
1325 m 1 -
2542 m 0.410.9 -
Weight = (0.50-1.00) t 8
Height (m) : 13 m 0.451.2 -
1325 m 0 -
2542 m -
Weight = (1.00-2.00) t 0.150.2
Height (m) : 13 m 4
1325 m 0.190.3 -
0 -
2542 m
0.230.3 -
8

0.080.1
3
0.090.1
6
0.100.1
7
4. 22F4 Transport with mobile crane t 3
Load weight (t):
- 0.50 t 0.5 -
- (0.501.00) t 0.240.3 -
 - (1.002.00) t 4 -
0.120.2
0
5. 22F3 Positioning and wedging of mobile 1 3 0.804 -
crane and local displacement within 20 statio
m. n

Example 5.1.
Describe the process of placing concrete into the slab of a building basement (Level -0.05 m). The quantity of
concrete to be placed is Q = 63 m3. The concrete class is Bc 15.

Solution:

I. Method Statement:

The quantity of concrete is fairly big, so manually mixing of concrete should be avoided. Consequently the
concrete will be provided by a ready-mix concrete plant. The concrete will be delivered with ready-mix
trucks of q T 3
C = 4.5 m capacity. The distance is D = 5 km and the average speed is s = 30 km/h. Concrete
will be placed with a concrete-pump.

Due to technological constraints (avoiding joints into the concrete structure) the placing work is required to be
fulfilled within a shift duration (one working day).

The structure of the work is given in Table 5.6 bellow, according to Norme de munc n constructii.

Table 5.6. Concrete placing by pumping into slab:

m NT NTU
Code Simple process UM Q (men) men hrs (hrs/UM
description )
U. M.

2B28 Pump positioning station 1 2 0.26 0.13

2B29 Pump priming prim. 1 2 1.05 -
2B20 Concrete pumping into m3 63 4 0.312 0.078
slabs

Other relevant information:

mix h
Performance rate of the ready-mix concrete plant: N TU 0.06 ;
m3
Concrete density before compaction: C = 2.2 t/m3;
Concrete density after compaction: C = 2.4 t/m3;
Temperature : = 15o C => setting time: = 1.25 h;
Cement: Pa 35
Time to manoeuvre the truck for loading: tml = 1.5 min.;
Time to manoeuvre the truck for discharging: tmd = 1.5 min;
Plant productivity factors (mixer and trucks): KFU 0.85.

II. Calculation steps

1. Determine the time needed to mix the concrete from a ready-mix truck (Eq.5.33)
mix c
t mix q c N TU ;< hrs > (5.33)
c
2.2
t mix 4.5 0.06 0.25 h
2.4
2. Determine the time remained for placing concrete from a ready-mix truck (Eq. 5.34).

t avpl t omax t ml t mix t D t md ;< hrs > (5.34)

where:
tml = 1.5 min
tmix = 0.25 h = 15 min
60 5
tD 10 min
30
tmd = 1.5 min
t pl = 1.25x60 - (1.5 + 15 + 10 +1.5) = 47 min = 0.78 h
av

3. Determine the time needed for a concrete-pump to place the concrete delivered with a truck mixer (Eq.
5.35)
c
t apl t p q c N TU
P
;< h > (5.35)
c
2.2
t apl t p 4.5 0.078 0.32 h
2.4

av
Equations (5.34) and (5.35) reveal that t pl > tp. Hence the work can be performed without using retarders or
any other adjustments.

4. Determine the gang size for placing concrete (Eq. 5.36)

M = mpl + maux ;< men > (5.36)
where:
mpl = optimum size of the gang which actually is involved in placing concrete into slab;
maux = auxiliary gang to assist the pump positioning and priming operations.
M = 4 + 2 = 6 men

5. Determine the actual time needed to place the whole quantity of concrete (Eq. 5.37)
Q N Tu
P
(5.37)
T t aux ;< h >
K PFU

where
taux = auxiliary time needed for positioning and priming the pump.
Consider two stations and one priming.
1.05
t aux 2 0.13 0.785 h
2
63 0.078
Thus: T 0.785 6.6 h
0.85
Consequently, the actual duration of the process is T a = 1 shift of 8 hours, for which the productivity factors of
the plant and operatives are
 6.6
P
K FU / I 0.825 K PFUmax 0.85
8

6. Determine the number of hauling units (ready-mix trucks) needed for carrying-out the pumping process:

(i) Number of transports needed (Eq. 5.38)

Q
nn ;< transports > (5.38)
qc

63
nn 14 transports
4.5

(ii) Number of transports a truck can perform within a day (Eq. 5.39)
d
np K Mix
FU K FU
T
;< transports > (5.39)
TT
TT = tml + tmix + 2tD + tmd + td ;< hours > (5.40)

where:
TT = round-trip time for a truck;
a
td = t pl = time needed to discharge a truck into the concrete pump (equals to the placing time)
1.5 10 1.5
TT 0.25 2 0.32 0.95 h
60 60 60
8
np 0.85 0.85 6 transports
0.95

(iii) Number of ready-mix trucks needed to transport the required quantity of concrete to be placed by
pumping (Eq. 5.41)
n
NT n ;< trucks > (5.41)
n pos
14
NT 2.3 trucks, hence consider N aT = 3 ready-mix trucks.
6

III. Final recapitulation

The above calculation steps reveal the following main data of the process (concrete pumping).
Time needed: Ta = 1 day;
Number of concrete transports: nn = 14 transports
Number of ready-mix trucks: NT = 3 trucks
Gang size: M = 6 men;

Productivity factor of operators and pump = 0.825