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 PROCESS OF
MANUFACTURE OF
CONCRETE

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• Production of quality concrete requires meticulous care
exercised at every stage of manufacture of concrete.

• 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.

• Therefore, it is necessary for us to know what are the good

rules to be followed in each stage of manufacture of concrete
for producing good quality concrete.

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 Various stages of manufacture of

(A ) BATCHING (B) MIXING (C ) (D ) PLACING

TRANSPORTING

(E) (F) FINISHING. (G) CURING

COMPACTING

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BATCHING OF CONCRETE
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 A. BATCHING

• The measurement of materials

for making concrete is known
as batching
• There are two methods of
batching
1.Volume batching
2.Weigh batching

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 Not a good method for proportioning because of its
difficulty to measure granular materials in terms of
volume
Used for unimportant and small concrete works

Volume of one bag of cement is 35 litres

1. VOLUME
BATCHING Gauge boxes are used for measuring aggregates

Volume of box is made equal to volume of one bag of

cement [35 litres]

Gauge boxes are generally made of timber or steel

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  It is the correct method of measuring materials
 More accurate , flexible and simple
 Type of weigh batcher depends on nature of job
 In small works , weighing arrangement consist of
two weigh buckets , connected through a system
of levers to spring loaded dials which indicate
load
2. WEIGHT  For large works , weighing is done through a lever
arm system and two interlinked beams and jockey
BATCHING weights
 In recent automatic weigh batching equipments,
recorders are fitted which record graphically the
weight of each material
 In small jobs , cement is not often weighed .
 It is added in bags assuming weight of bag as
50 kg

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B. MIXING OF CONCRETE

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 MIXING
• Process of combining the constituent raw materials, used for
concreting, along with water to make concrete
• Thorough mixing is essential for production of a uniform
concrete.

Requirements of a good mix concrete are

i. Should be homogeneous
ii. Uiform colour
iii. Consistent.

Mixing of concrete can be done in two ways:

iv. Hand mixing
v. Machine mixing
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• Methods of mixing

i. Hand mixing:

Used in small scale works.

As mixing cannot be thorough and efficient usually 10% more cement is added to compensate for
inferior concrete quality.

Mixing must be done on an impervious floor of sufficiently large size to accommodate the mass.

Spread out the coarse aggregates and fine aggregates in

alternate layers and mix them thoroughly.

Then add cement and dry mix the mass till a uniform colour is obtained.

Then sprinkle water slowly till a uniform mix is obtained.

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ii. Machine mixing:

Used for large scale works using machines.

Produces an efficient, economical and uniform concrete.

The efficiency of mixer depends upon i.shape of the drum

ii. angle of blades iii. and size of blades

iv. angle at which drum is held.

Usually, after machine mixing is done and poured on floor, hand mixing is also done.

For mixing, 25% of total water is introduced into mixer to wet the drum

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 Mixers are available in two types as
i. Batch mixers
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ii. Continous mixers.

 In Batch mixing concrete is produced batch by batch at regular

time intervals.Batch mixers may be of pan type or drum type.
 Drum type may be of Tilting, Non-Tilting and Reversed.In
continousmixing concrete is produced continuously without
stoppage.
 Materials are fed continuously and concrete is discharged
without stoppage.
 Used in very large works like in Dams, etc.

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C. TRANSPORTING OF CONCRETE
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PLACING OF CONCRETE
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 PLACING CONCRETE
WITHIN EARTH
MOULD [eg. :
foundation]
• Before placing concrete in
PLACING foundation , all loose earth , that
OF is roots of trees etc. will
removed from the bed
CONCRETE • If earth’s surface is dry , just
damp it so that the earth won’t
absorb water from concrete
• If earth surface is too wet , water
should remove before placing
concrete

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 PLACING OF CONCRETE WITHIN LARGE EARTH
MOULD [eg : road slab]
• Ground surface in which concrete is placed must be free
from loose earth , pool of water , organic matter , etc.
• Earth should be properly compacted and damped
• Concrete is laid is alternative bays to undergo sufficient
shrinkage
• Concrete must be damped and not poured

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 PLACING CONCRETE IN LAYERS WITHIN
SHUTTERS
• Eg. Mass concrete in dam construction
• For mass construction , concrete is placed in layers
• Thickness of layers depends upon mode of compaction
• For reinforced concrete , thickness of layer varies
between 15 to 30 cm
• For mass concrete , thickness varies from 35 to 45 cm
• Cold joints must be avoided

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 PLACING CONCRETE WITHIN USUAL
FORM WORK
• Eg. Columns , beams and floors
• Before placing concrete , check the
reinforcement is correctly tied , placed and
have appropriate cover
• Reinforcement should be clean and free from
oil

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PLACING CONCRETE UNDER WATER
• Bottom dump bucket is generally used
• In bottom dump bucket method , it will not give a satisfactory result
• Tremic pipe is a pipe of diameter 20 cm capable of easy coupling
for increase or decrease of length
• Funnel is fitted to top end and bottom end is closed with plug and
taken below water and made to rest at the point where concrete is to
be placed
• Since end is blocked , no water will enter the pipe
• When pipe is raised and given a jerk , due to weight of concrete ,
concrete is discharged

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 SLIP FORM TECHNIQUE
• Used for placing concrete for both vertical and
horizontal construction
• Concrete is continueosly placed , compacted ,
and formwork is pilled up by member of
hydraulic jack
• Rate of slipping the framework vary
depending upon the temperature and strength
development of concrete

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COMPACTION OF CONCRETE
• It is the process adopted for expelling the entrapped air from
the concrete
• In the process of mixing , transporting and placing of
concrete air is likely to get entrapped in the concrete
• Lower the workability , higher is the amount of entrapped air
in the concrete
• If this air is not removed fully , concrete losses strength
considerably
• In sufficient compaction increases the permeability of
concrete resulting in easy entry for aggressive chemicals
which attack concrete and reinforcement to reduce durability

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 Methods adopted for compaction of
concrete
a. HAND COMPACTION
 Rodding
 Ramming
 Tamping
b. COMPACTION BY VIBRATION
• (i ) Internal vibrator (Needle vibrator)
• (ii ) Formwork vibrator (External vibrator)
• (iii ) Table vibrator
• (iv ) Platform vibrator
• (v ) Surface vibrator (Screed vibrator)
• (vi ) Vibratory Roller.
c. COMPACTION BY PRESSURE AND JOLTING
d. COMPACTION BY SPINNING

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 Hand Compaction
• It is adopted in case of unimportant concrete work of small
magnitude
• When hand compaction is adopted , consistency of concrete is
maintained at a higher level
• Thickness of the layer of concrete is limited to about 15 to 20 cm
• Rodding is nothing but poking the concrete with about 2 metre long
, 16 mm diameter rod to pack the concrete between the
reinforcement and sharp corners and edges
• Rodding is done continuously over the complete area to effectively
pack concrete and drive away the entrapped air
• Instead of iron rod , bamboos or cane is also used for rodding
purpose

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• Ramming should be done with care
• Light ramming can be permitted in unreinforced foundation
concrete or in ground floor construction
• Ramming should not be permitted in reinforced concrete or in
upper floor construction
• If ramming is adopted in above case, position of
reinforcement may be disturbed or framework may fail
• Tamping is one of the usual methods adopted in compacting
roof or floor slab or road pavements where the thickness of
concrete is comparatively less and surface to be smooth and
level

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 Compaction by Vibration
• Compaction by hand , if properly carried out on
concrete with sufficient workability , gives
satisfactory results , but the strength of hand
compacted concrete will be necessarily low because
of higher water cement ratio
• Where high strength is required , it is necessary that
stiff concrete with low water cement ratio to be used
• To compact such concrete , mechanically operated
vibratory equipment must be used

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 Internal vibrator
• Most commonly used
• Also known as needle vibrator , immersion vibrator or
poker vibrator
• it consist of a power unit , a flexible shaft and a needle
• Power unit may be electrically driven or operated by
petrol or air compressor
• Vibrations are caused by eccentric weights attached to
the shaft
• Frequency of vibration varies 12000 cycles of per minute

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 Table vibrator
• It is a type of vibrator in which vibrator is
clamped to a table
• Used for vibrating concrete cubes
• Any article kept on table will get vibrated
• This is mostly adopted in the laboratories and
in making small but precise prefabricated RCC
members

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 Platform vibrator
• It is a table vibrator but large in size
• Used in manufacture of large prefabricated concrete
elements such as electric poles , railway sleepers ,
prefabricated roofing elements etc.
SURFACE VIBRATOR
• Also known as screed board vibrators
• A small vibrator placed on the screed board gives an
effective method of compacting and levelling of thin
concrete members , such as floor slabs , roof slabs and
road surface
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 COMPACTION BY PRESSURE AND
JOLTING
• An effective method for compacting very dry
concrete
• Used for compacting hollow bricks , cavity
blocks and solid concrete blocks
• With the combined action of the jolts
vibrations and pressure , stiff concrete gets
compacted to a dense form to give good
strength and volume stability

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 COMPACTION BY SPINNING
• Spinning is one of the recent method of
compaction of concrete
• It is adopted for the fabrication of concrete pipes
• The plastic concrete when spun at a very high
speed , gets well compacted by centrifugal force
• Products like hume pipes , spun pipes are
compacted by spinning process

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FINISHING OF CONCRETE
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CURING OF CONCRETE

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a. Water curing
(a ) Immersion
(b) Ponding
(c ) Spraying or Fogging
(d ) Wet covering Curing

b. Membrane curing

c .Application of heat
(a) Steam curing at ordinary pressure.
(b) Steam curing at high pressure.
(c) Curing by Infra-red radiation.
(d) Electrical curing.
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