CIVIL ENGINEERING WORKSHOP PRACTICE

Course code: CVL 1013

Program: B. Tech.
Semester: First (Credit: 4)

Course instructor
Mrs. Rashmisikha Behera
Assistant Professor, Department of Civil Engineering
Faculty of Engineering & Technology
Institute of Technical Education & Research
Siksha ‘O’ Anusandhan deemed to be University
Bhubaneswar, Odisha-751030, India
Concrete
 Concrete

 Concrete is the final product resulting from mixing cement,

aggregates (including sand), water, and admixtures together.

 It is initially malleable in its “wet” state and solidifies over time,

gaining strength and durability.

 Concrete mixes vary based on strength, appearance, and local

requirements
 Concrete

Applications of cement concrete

Foundation
of Building
Concrete
Applications of cement concrete Foundation of Building
Concrete
Applications of cement concrete Column and Beams of Building
Concrete
Applications of cement concrete Column and Beams of Building
Concrete
Applications of cement concrete Roof/chajja of Building
Concrete
Applications of cement concrete
Rail line sleeper
Drain structure

Port Airport taxiway

Concrete
Applications of cement concrete Bridge
Concrete
Applications of cement concrete Retaining wall
Concrete
Applications of cement concrete Top layer of Road
 Concrete
It is typically made from four key ingredients :

Cement Sand Aggregates

Cement
concrete

Water
Concrete
Functions of cement
o It fills up voids existing in the fine
aggregate and makes the concrete
impermeable.
o It provides strength to concrete on setting
and hardening.
o It binds the aggregate into a solid mass by
virtue of its setting and hardening
properties when mixed with water.
Concrete
Functions of aggregates
o In the cement concrete, to provide good quality
of concrete aggregate is used in two size
groups.
o Coarse aggregate – Particle size more than
4.75mm
o Fine aggregate (sand) particle size less than
4.75mm

o Coarse aggregate makes solid and hard mass of concrete with

cement and sand.
o It increases the crushing strength of concrete.
o It reduces the cost of concrete, since it occupies major volume.
Concrete
Functions of aggregates
o Coarse aggregate – Particle size more than
4.75mm
o Fine aggregate (sand) particle size less than
4.75mm
Single size Wide range of sizes
Concrete
Damages due to permeability
Concrete
Functions of sand
o It fills the voids existing in the coarse
aggregate.
o It reduces shrinkage and cracking of concrete.
o By varying the proportion of sand concrete can
be prepared economically for any required
strength.
o It helps in hardening of cement by allowing the
water through its voids.
 Concrete
Functions of water
o Water is only the ingredient that reacts
chemically with cement and thus setting and
hardening takes place.
o Water acts as a lubricant for the aggregate and
makes the concrete workable.
o It facilitates the spreading of cement over the
fine aggregate.

o Hydration to create a chemical reaction with the cement

o To aid in the workability (ratio of water to cement)
Concrete
Characteristics of well mixed concrete
 Concrete should be of uniform colour.
 All concrete materials like cement, fine aggregates,
coarse aggregates and water should be
homogeneously mixed.
 Cement paste should cover all the surface of the
aggregate.
 Segregation or bleeding of concrete should not occur
after the concrete mixing.
 Concrete
Concrete Manufacturing Processes Overview
o Batching

The first step involves gathering the ingredients necessary to produce the
particular type of concrete. The type of batching, volume or weighted, is
contingent on the amount of concrete being produced.
o Mixing

Depending on the type and quantity needed for a particular job, concrete can be
mixed by hand, by stationary mixer, or during transport.
o Transporting and Placing

Methods of transporting concrete vary widely from wheelbarrow and manual

hauling to conveyor belt operations, to more advanced projects involving cranes
and pumps.
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 Concrete

Concrete Manufacturing Processes Overview

o Compacting and Placing

During mixing and transport air is often entrapped, greatly reducing the quality
and strength. One of the final stages of production involves compacting the
product to eliminate the air pockets and ensure durability..
o Curing and Finishing

This process takes place immediately after concrete is compressed and involves
close attention to detail regarding moisture levels and contracting as it dries.
This process is crucial in preventing cracking and durability issues.

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Concrete
Hand Mixing of concrete
 Requires special skills and care during the process.
 Mixing by hand is employed only to specific cases where quality
control is not of much importance and quantity of concrete required
is less. 
 The main purpose of mixing the concrete is to obtain a uniform
mixture that shows uniformity in terms of color and consistency.
Concrete
Hand Mixing of concrete

Dry blending Addition of water

Cement concrete Blending with water

Concrete
Hand Mixing of concrete
 Measured quantity of sand is spread evenly.
 The required quantity of cement is dumped on the sand and spread
evenly.
 The sand and cement is then mixed intimately with spade, turning
the mixture over and over again until it is of even color throughout.
 The measured quantity of coarse aggregate is spread out and the
sand cement mixture is then spread on its top.
 The whole mass should be mixed at least three times by shovelling
and turning over by twist from centre to side, then back to the
centre and again to the sides.
Concrete
Hand Mixing of concrete
 A hollow is made in the middle of the mixed pile.
 Three quarters of the total quantity of water required should be
added while the materials are turned in towards the center with
spades.
 The remaining water is added by a water-can fitted with rose
head, slowly turning the whole mixture over and over again until
a uniform color and consistency is obtained throughout the pile.
 5 percent extra cement shall be added than the specified for
machine mixing, when hand mix cement concrete is produced.
 The mixing platform should be washed at the end of the day.
Concrete
Hand Mixing of concrete

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 Concrete
Machine Mixing of concrete
 Process of mixing the ingredients of the
concrete with a concrete mixer machine.
 It is highly effective for fulfilling the
demands of short mixing time, optimum
consistency and homogeneous quality of
concrete.
 Machine mixing of concrete imparts the
uniformity of the mix without disturbing
uniformity.
 Machine mixing of concrete is most suitable
in the large projects because it ensures the
consistent homogeneity of the concrete.
 Concrete
Machine Mixing of concrete
Process of Machine Mixing of Concrete:
 First of all, wet the inner surfaces of the drum of concrete mixer.
 Coarse aggregates are placed in the mixer first followed by sand and then
cement.
 Mix the materials in the dry state in the mixing machine. Normally it should
be 1.5 to 3 minutes.
 After proper mixing of dry materials, gradually add the correct quantity of
water while the machine is in motion. Excess water is not advisable as it
reduces strength.
 After adding the water, you must mix concrete for a minimum of two
minutes in the drum.
 If there is any segregation of concrete after unloading from the mixer, then
remix the concrete.
Concrete
Machine Mixing of concrete
Precautions to be Taken While Machine Mixing of Concrete:
 Concrete mixer machine must be wet before use.
 Take care of mixing time, speed and numbers of revolution of mixer drum
as per the recommendation of the manufacturers of the mixer machine.
 Concrete should be used within 30 minutes after mixing and discharged by
the concrete mixer.
 If your mixing is batch type then, after discharging one batch of concrete,
the interior surface of the mixer drum should be cleaned thoroughly.
 If your mixing is of a continuous type, it is necessary to clean the concrete
mixer after fixed intervals.
 The inner portion of the concrete mixer should be carefully inspected at
regular intervals to check for damages, shatter or corrosion.
Concrete
Machine Mixing of concrete

Transferring
ingredients into
drum

Ingredients

Machine drum mixing with

rotational movement
Cement concrete
Concrete
Machine Mixing of concrete

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Concrete
Ready Mix concrete

 In India, on-site production of the conventional concrete with the

use of labour force and with the primitive mixer machine equipment
is very commonly used.
 The ready mix concrete is also becoming popular nowadays.
 Ready Mix Concrete (RMC) is a specialized material in which the
cement, aggregates and other ingredients are weighed and batched
at a plant at a central location, then mixed either in a central mixer
or in truck mixers, before being delivered to the construction site in
condition ready for placing by the customer.
Concrete
Ready Mix concrete

 The quality of resulting concrete is much better than the site-mixed

concrete i.e. both the hand mixed and machine mixed concrete.
 Ready mix concrete is particularly useful on congested sites or in
road construction where there is little space or no space available
for a mixing plant or for storage of aggregates.
 quality control of concrete is easy as the batching and mixing of
concrete is done at the mechanized central batching plant.
 This method of mixing is very useful for several places i.e. in
congested area, at night concreting work, at large construction site
etc.
Concrete
Ready Mix concrete

RMC plant
Concrete
Ready Mix concrete

Ingredients
Mixing in RMC plant

Placing of concrete at
site
Concrete
RMC plant

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Concrete vibrators
Since concrete contains particles of different sizes, the most
effective compaction of concrete can be achieved by using vibrators
with different speeds of vibration.

Types of Concrete Vibrators
1. Immersion or needle vibrator

2. Extended or shutter vibrator

3. Surface Vibrator

4. Vibrating table
Concrete vibrators
Immersion or Needle Vibrators
 Immersion or Needle Vibrators are most commonly used vibrator for
concrete.
 It consists of a steel tube (with one end closed and rounded) having an
eccentric vibrating element inside it.
 This steel tube called poker is connected to an electric motor or a diesel
engine through a flexible tube.
 The period of vibration required may be of the order of 30 seconds to 2
minute. The concrete should be placed in layers not more than 600mm
high.

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Concrete vibrators
External or Shutter Vibrators
 These vibrators are clamped rigidly to the form work at the pre-
determined points so that the form and concrete are vibrated.
 They consume more power for a given compaction effect than internal
vibrators.
 These vibrators can compact upto 450mm from the face but have to be
moved from one place to another as concrete progresses.
 These vibrators operate at a frequency of 3000 to 9000 rpm at an
acceleration of 4g.
 The external vibrators are more often used for pre-casting of thin in-
situ sections of such shape and thickness as can not be compacted by
internal vibrators.

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Concrete vibrators
Surface Vibrators for Concrete
 These are placed directly on the concrete mass.
 These best suited for compaction of shallow elements and should not be
used when the depth of concrete to be vibrated is more than 250 mm.
 Very dry mixes can be most effectively compacted with surface vibrators.
 The surface vibrators commonly used are pan vibrators and vibrating
screeds.
 The main application of this type of vibrator is in the compaction of small
slabs, not exceeding 150 mm in thickness, and patching and repair work of
pavement slabs.
 The operating frequency is about 4000 rpm at an acceleration of 4g to 9g.

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Concrete vibrators
Concrete Vibrating Table
 The vibrating table consists of a rigidly built steel platform mounted on
flexible springs and is driven by an electric motor.

 The normal frequency of vibration is 4000 rpm at an acceleration of 4g to

7g.

 The vibrating tables are very efficient in compacting stiff and harsh
concrete mixes required for manufacture of precast elements in the
factories and test specimens in laboratories.

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