Shrink Mixed Concrete

Shrink Mixed Concrete

Concrete that is partially mixed in a plant mixer and then discharged into the drum of the truck mixer for completion of the mixing is called shrink mixed concrete. Central mixing plants that include a stationary, plant-mounted mixer are often actually used to shrink mix, or partially mix the concrete. The amount of mixing that is needed in the truck mixer varies in these applications and should be determined via mixer uniformity tests. Generally, about thirty turns in the truck drum, or about two minutes at mixing speed, is sufficient to completely mix shrink-mixed concrete.

Transit Mixed Concrete

Transit Mixed Concrete

While ready mixed concrete can be delivered to the point of placement in a variety of ways, the overwhelming majority of it is brought to the construction site in truck-mounted, rotating drum mixers. Truck mixers have a revolving drum with the axis inclined to the horizontal. Inside the shell of the mixer drum are a pair of blades or fins that wrap in a helical (spiral) configuration from the head to the opening of the drum. This configuration enables the concrete to mix when the drum spins in one direction and causes it to discharge when the direction is reversed.

To load, or charge, raw materials from a transit mix plant or centrally mixed concrete into the truck, the drum must be turned very fast in the charging direction. After the concrete is loaded and mixed, it is normally hauled to the job site with the drum turning at a speed of less than 2 rpm.

The traditional truck-mixer has discharged concrete at the rear of the truck. Front discharge units, however, are rapidly becoming more popular with contractors. The driver of the front discharge truck can drive directly onto the site and can mechanically control the positioning of the discharge chute without the help of contractor personnel.

Currently, because of weight laws, the typical truck mixer is a 7 to 8.5 m3. The drums are designed with a rated maximum capacity of 63%  of the gross drum volume as a mixer and 80% of the drum volume as an agitator. Generally, ready mixed concrete producers, load their trucks with a quantity at or near the rated mixer capacity. Fresh concrete is a perishable product that may undergo slump loss depending on temperature, time to the delivery point on the job site, and other factors.

Equipment Required in Ready Mix Concrete

Equipment Required in Ready Mix Concrete

Following are the equipments required in Ready Mix Concrete

1.Batching plant

2.Transit mixer

BATCHING

Batching plants are classified as

1.Manual

2.Semiautomatic

3.Fully automatic

STORAGE

Storage of the raw materials is done by following methods: -

INLINE BINS Inert raw materials like fine & coarse aggregates are stored in bins called as

“Inline Bins” where the trucks carrying fine & coarse aggregate can dump the material easily.

The aggregates required are fed by the means of aggregate belt conveyer. On the aggregate belt conveyer the aggregates are weighed automatically by means of computer form the computer room presents on the plant.

SILOS

Cement & Flash are stored in airtight container called as “Silos”. The required quantity of cement & fly ash is extracted by the silos. There are two cement silos and one silo of fly ash.

Material Required for Ready Mix Concrete

Material Required for Ready Mix Concrete

Admixture: A substance added to the basic concrete mixture to alter one or more properties of the concrete; ie fibrous materials for reinforcing, water repellent treatments, and coloring compounds.

·     Air-entraining admixtures (mainly used in concrete exposed to freezing and thawing cycles)

·     Water-reducing admixtures, plasticizers (reduce the dosage of water while maintaining the workability)

·     Retarding admixtures (mainly used in hot weather to retard the reaction of hydration)

·     Accelerating admixtures (mainly used in cold weather to accelerate the reaction of hydration)

·     Super plasticizer or high range water-reducer (significantly reduce the dosage of water while maintaining the workability)

·     Miscellaneous admixtures such as corrosion inhibiting, shrinkage reducing, coloring, pumping etc.

Aggregate: Inert particles (i.e. gravel, sand, and stone) added to cement and water to form concrete.

Cement: Dry powder that reacts chemically with water to bind the particles of aggregate, forming concrete. Portland cement is typically used in concrete production.

Fly ash: Fly ash is a by-product from coal-fired electricity generating power plants. The coal used in these power plants is mainly composed of combustible elements such as carbon, hydrogen and oxygen (nitrogen and sulfur being minor elements), and non-combustible impurities (10 to 40%) usually present in the form of clay, shale, quartz, feldspar and limestone.

Scope of Ready Mix Concrete

Scope of Ready Mix Concrete

Long, Long years ago, their where simple houses but in 21st century we can see houses constructed in R.C.C. Therefore concrete got more importance than any other construction material. So the use of concrete is increasing day by day.

For construction most of the contractors and builders have to collect the raw materials required for the construction before starting actual works. These materials should be stored at the site properly. This technique can be possible when there will be more empty space at the construction site which is not possible in congested areas. At this time there is one solution to overcome all these problems that is nothing “READYMIX CONCRETE”.

By using R.M.C we can save the time and money required for the labors. In following places ready mix concrete can be used:-

·     Major concerting projects like dams, roads, bridges, tunnels, canals etc.

·     For concreting in congested areas where storage of materials is not possible.

·     Sites where intensity of traffic makes problems.

·     When supervisor and labor staff is less.

·     To reduce the time required for construction etc.

·     Huge industrial and residential projects.

Checks Needed at Site During Concreting

Checks Needed at Site During Concreting

Proper co-ordination between the Ready Mix Concrete supply and placing and compacting gangs.

·     Proper signaling or communication at site is necessary.

·     Workability of concrete within accepted limits.

·     Adequacy of cohesiveness of concrete for pump ability.

·    Ensure that water addition or chemical admixtures are not added during transportation by RMC unauthorized persons and without the knowledge of the site in charge of the consumer.

·     Temperature of concrete at the time of receipt at site (if specified).

·     Continuous and steady supply at site and speedy unloading of the Monitor speed and progress of placing to avoid formation of cold joints transit mixers.

·     Monitor proper  placement without segregation.

·     Monitor placement of concrete at the closest possible point to its final location.

·     Arrange for curing as soon as finishing is completed. This is specially required in case of slabs, pathways and roads in hot/warm weather.

·     Retempering should be prohibited as experiments shows the addition of water to RMC truck at the construction site may result in substantial reduction in strength. The reduction in strength was found to be proportional to the increase in slump. Large increase in slump means higher reduction in strength. When the amount of water added is not controlled, reduction of strength may be as high as 35%. In cases where controlled amount of water is added to restore the slump within the specification’s limits (100 ±25 mm), the reduction of strength may be below 10%.

Check by Consumer Before Ordering the Ready Mix Concrete

Check by Consumer Before Ordering the Ready Mix Concrete

The following need to be looked into by the consumer:

·     Reliability of the plant and transit mixers for consistent and continuous concrete supply as per requirement.

·     Calibrations of all measuring devices and their accuracy.

·     Mode of operation of plant should preferably be fully automatic and not manual.

·     Quality of materials proposed to be used.

·     Adequacy of quantity of materials proposed to be used.

·     Compliance of concrete specifications based on the mix parameters specified.

·     Adequacy of testing facilities

·     Time likely to be taken by transit mixers from plant to site and back.

Information to be Supplied by the Producer

Information to be Supplied by the Producer

The Ready Mix Concrete supplier must provide the following information to the consumer if and when requested:

·     Nature and source of each constituent material including the name of the manufacturer in case of branded products like cement, admixtures etc.

·     Proportion of quantity of each constituent per CuM of fresh concrete.

·     Generic type of the active constituent of the chemical admixture and its solid content.

·     Chloride content in all constituent materials.

·     Compatibility of cement and chemical/mineral admixtures.

·     Compatibility of admixtures with one another when more than two types of admixtures are proposed.

·     Initial and final setting time of concrete when admixture is used.

·     Details of plant and machinery (capacity CuM/hr), storage (CuM) availability, type of facilities to dose admixtures, type of moisture measurement arrangement, type of mixer, rated capacity (CuM/min.) of the mixer.

·     Availability of number of transit mixers and their capacities.

·     Details of last calibrations done on various weighing /dosing equipments

·     Testing facilities available at RMC plant

·     Capacity and type of concrete pump and placing equipment available (if required).

Need to be Specified for Ready Mix Concrete

Need to be Specified for Ready Mix Concrete

The following need to be specified very clearly:

·     Characteristic strength or grade (N/mm2)

·     Target workability or slump in mm required at site

·     Exposure conditions for durability requirements

·     Maximum water to cement ratio

·     Minimum cement content

·     Maximum aggregate size

·     Type of cement

·     Mineral admixture and its proportion (Kg/m3)

·     Maximum aggregate size

·     Rate of gain of strength (for formwork removal or prestressing etc.)

·     Maximum temperature of concrete at the time of placing (in extreme climatic conditions or incase of massive concrete pours)

·     Type of surface finish desired

·     Method of placing

·     Rate of supply desired to match the placing and compaction speed planned at site.

·     Quantity of concrete required.

·     Lift and lead of concrete transportation and placement at site.

·     Frequency of concrete testing

·     Details of materials and their required tests.

·     Permeability tests required (if any)

·     Placing of concrete in formwork to be under scope of RMC supplier (if required)

·     Permissible wastage

·     Mode of measurement.

Use of Fly Ash Based in Concrete

Use of Fly Ash Based in Concrete

To have a better performance characteristics in terms of durability of concrete, fly ash is been used successfully in concrete. The improvement in gel structure caused by pozzolanic action of fly ash leads to a very impervious concrete. These factors improve the resistance of concrete against external aggression. Since Fly ash is an environmental hazard, therefore by effectively using it in concrete it can be consumed constructively and thus contribute to the ecological balance. Many prestigious and critical structures have been built using either PPC or  by blending fly ash directly in concrete. The names of the famous Petronus towers & Eurotunnel can be definitely quoted in this regard. However , the  construction industry has offered some resistance in using PPC or fly ash in structural concrete. With advent of RMC the doubts regarding controls in using this material are slowly dispelled and engineers have become more open to the idea of using fly ash as pozzolan for partial replacement of cement in concrete.

“Limestone is the raw material for the manufacture cement & limestone is limited resource.” It cannot last long it ever. We need to realize the importance of this fact. We need to use our cement rationally. Whereas we talk about huge figure describing development and building needs of our country, concrete still remains the most widely used and environmental friendly construction material to achieve this.

Admixtures

Admixtures

Ready Mix Concrete is generally transported to different construction sites and delivered with the help of revolving type transits mixers. These sites are located at long distances and the concrete delivered is workable, plastic and flowable. Experience shows that slump loss takes place with certain types of cement and to prevent this superpplasticiser are used.

Ready Mix Concrete's often use admixtures formulated for special purposes lik e:

(a) Improvement of screeds, renders, mortars and concrete for increased water resistance and less risk - from aggressive materials,

( b) Integral water proofers,

 (c) Foamed - for light weight insulation. void filling and semi structural support,

(d) Water repelling for semi-dry block concrete,

(e) Microsillica for use in high performance concrete. The introduction of microsillica was observed to improve the pore solution chemistry of HPC. For higher replacement of cement by silica fumes, the concentration of both K+ and OH-ions are substantially removed. However, up to 20% replacement will not cause a drop in pH below that of saturated CaOH solution, which is approx.12.5. Even at 30%

replacement,  pH does not drop below 11.5, which is considered to be a threshold value for maintaining a good passivity of embedded steel.

Testing of Concrete

Testing of Concrete

The results of concrete tests are used as the basis for deciding whether the delivered concrete is in accordance with the specification, if the reported results are below the compliance loyal, doubt is cast on the quality of the supplied concrete and the long term durability of the structure. If the investigation indicates that the sampling, preparation and or storage of the test specimens have not been in accordance with the required standard procedures, then the result will be invalid. Further valuable management time, better devoted to other management functions, will have been wasted.

It is, therefore, in everyone's interest that sampling and testing is done correctly so that the results provide a valid basis for logical decision making. Where the contractor is required to perform on-site concrete testing, it is imperative that suitable test facilities are available, that the appropriate equipment is calibrated and that the staff has been fully trained in the relevant test techniques, one can look the factors that affect the price compliance test, (i.e.) the compressive strength test.

As  a result is the average of the compressive test specimens made for the same sample of concrete. Individual variation should not be more than 15 Percent of the average. If more. The results of the average. If more, the results of the sample are invalid. This is because differences of this magnitude indicate poor sampling, cube making, curing or crushing. It is, therefore essential that correct test facilities are provided and the people with responsibility for sampling and testing concrete are suitably trained.

Slump test for predicting the workability of concrete is done at batching plant and working site. The main problem in the production of ready mixed concrete is maintaining the workability of the mix right to the time of placing. Concrete stiffens with time and the stiffening may also be aggravated by prolonged mixing and by high temperature. With the use of retarding admixtures, the time limit can be extended to 3 or even 4 hours, The United States Bureau of Reclamation provides for an extension of 3 to 6 hours in the time of contact between cement and wet aggregate in transport prior to mixing.  The general requirement is that concrete shall be discharged from the truck-mixer within 2 h of the time of loading. However, a longer period may be permitted if retarding admixtures are used or in cool humid weather or when chilled concrete is produced.

Sampling of Concrete

Sampling of Concrete

Critical decisions, often involving very high potential costs, are made on the basis of concrete test results. Correct sampling is paramount to the validity of these test results but is an aspect of testing that is frequently overlooked and often carried out by untrained people. It is therefore essential that the sampling is done correctly and is representative of the concrete delivered.

After the truck-mixer has re-mixed its delivery on site allow at least the first one-third of a m3 of concrete to be discharged prior to taking any samples. Take at least 4 incremental samples from the remainder of the load avoiding sampling the last cubic meter of concrete. Thoroughly re-mix this composite sample either on a mixing tray or in the sampling bucket and proceed with the required testing.

Describe the recommended sampling methods for ready mixed concrete in British code. Using a standard scoop, this can collect about 5kg of normal weight concrete. Each load of concrete to be tested should be nominally divided into a number of scoopfuls.

The Standard method: To ensure that the concrete is representative of the whole load is standard sample consists of scoopfuls taken from at least four different parts of the load and collected in buckets. The scoopfuls should be taken at equally spaced intervals; the scoop being passed through the whole width and thickness of the stream in a single movement. The first and the last 1/6th

portion of the discharge should be disregarded as unrepresentative. This is then thoroughly re-mixed on a non-absorbent surface before carrying out any individual test. This operation is necessary to even out any variation between individual scoopfuls and to counteract any segregation that may have occurred in transporting the sample from the sampling point to the testing area.

The Alter native Method: An alternative method of sampling concrete for slump testing from

a truck-mixer before the majority of the load has been discharged is permitted. This enables the concrete to be tested before being placed. When this alternate method is used, an initial discharge of at least 0.3 m3 is made before a sample of six scoopfuls is collected from the

moving stream; The sample is then r e-mixed on a non-absorbent surface and split into two equal parts. Each part is then tested or slump, with the average of the two tests recorded as the test result. This method of sampling is only applicable to the slump test. Concrete sampled by this method must not be used to make cubes for compliance testing, as it will produce erroneous results.

Batching and Mixing Plants

Batching and Mixing Plants

The principal functional elements of every stationary concrete production Plant comprises of the following:

·     Storage of materials - Silos, containers and bins

·     Batching arrangement

·     Measuring and recording equipment

·     Mixing equipment

·     Control systems

·     Electrical, hydraulic and pneumatic drives
·     Conveying systems (belt / screw conveyors)