Safety When Portland cement is mixed with water, or even when it becomes damp, alkalis are released which can be harmful to the human skin. The harmful effect depends on the period of contact, prior abrasion, individual's health, and the part of the body involved. To avotd harmful effects, suitable protective clothing should be worn. If eyes get affected they should be immediately washed and medical attention sought. Copyright © 2008 RMC Readymix (I) Pvt Ltd. The tips/Information in this publication is intended purely as guid: Users of this information are advised to evaluate the significance and limitations of its contents and take full responsibilty for its use and application. No liability (including thal for negligence) for any loss resulting from such guidance information is accepted. Readers should also note that this publication is subject to revision from time lo time and should therefore ensure thal they are in possession of the latest version.Foreword This guide is produced to assist field personnel and provide them with tips on good practices to be followed in placing, compacting and curing concrete It provides guidance on: Equipment Placing concrete Compacting concrete Compaction queries Curing of concrete Don't forget: * POOR COMPACTION = POOR CONCRETE = lower strength high porosity = honeycombing blow holes = lower durability + POOR CURING = POOR CONCRETE = lower strength dusty surface weaker surface = lower abrasion resistance = lower durability. Always inspect the formwork and reinforcement before placing concrete. Ensure that the formwork is strong, adequately braced for safely and leak-proof. Double-check dimension, rigidity, reinforcement details and builtin items.The aim of good concrete placing Is quite simple. tis to get the concrete into position quickly and in a condition that allows it to be compacted and finished correctly and with ease. Lie Cell ley fee) estas Wherever possible, discharge directly from the truckmixer. If concrete needs to be discharged at elevated locations, this can done with the help of a concrete pump, or crane and bucket or a conveyor. General tips When concrete is placed, alr gets trapped. If this Is not removed by Vibration induced through compaction, the air voids tend to weaken the concrete and make pathways for entry of moisture, and other aggressive chemicals within the Concrete mass. The voids may also reduce the bond between concrete and reinforcement. On many occasions, inadequate compaction may get manifested in honeycombing in hardened concrete. It has been established that for every 1% of entrapped alr, around 5-6% of concrete strength will be lost. This, highlights the importance of compactionEnsure adequate access to the pour. Carefully place the concrete in a series of layers of equal depth - normally, no more than 300 to 500 mm deep, PLACING CONCRETE Don't allow the concrete to pile up in large heaps or sloping layers General tips Deep sections such as walls and columns need extra care. Concrete should not be allowed to free-fall too far - preferably no more than 1m. Where necessary use letter boxes, windows, a tremie pipe or concrete pump to place concrete in the forms. Use of a Truckmixer fitted with Conveyor is also advantageous in some such applications.eve ley ONCRETE General tips > All forms must be rigid, level and Ensure that inside portion is cleaned up before any concrete is placed. Always make sure there is adequate safe access to the discharge point for personnel and equipment Wherever possible, use the truckmixer chute to discharge concrete directly into its final position. This will save time, effort and money. When placing concrete in slabs, always leave a surcharge, of al least 15 mm, to allow for settlement as the concrete is compacted.If light mesh reinforcement is required near the top of the slab: * compact the concrete upto mesh level with a notched beam * lay mesh reinforcement * cover with concrete, compact and finish * avoid treading on the mesh and forcing it deeper into the slab. Asan alternative to light mesh reinforcement, use Fibre-reinforced Concrete. Added into the mix at the plant, millions of polypropylene fibres are uniformly dispersed throughout the load and give the following benefits. + Always correctly positioned + truckmixer can reverse into bays * reduces plastic shrinkage cracking * Improves abrasion resistance + Improves impact resistance * reduces permeability * increases durability + improves cohesion. PLACING CONCRETE Concreting slabs —& NYLee ley CONCRETE General tips > Use Telescopic Conveyor for Versatility in Operation + An operation radius of 310%and a reach of 14 metres offers a substantial placing range Allows placement of concrete precisely, in hard-to-reach spots + Provides unparalleled safety, flexibility and visibility to the conveyor operator This “one-man, one-machine” is an independent Total Delivery Unit that can be used even in interior building locations.Compaction entails the removal of entrapped air bubbles from the concrete. To correctly compact concrete you will generally need one or more of the following: Poker vibrators - These are the most popular type of vibrator for compacting concrete. Clamp-on vibrators - These are fixed to formwork ( hence, often known as shutter vibrators) and are used to compact concrete when access for poker vibrators is unobtainable. For example, in pre-cast concrete elements, heavy density of reinforcement makes pokers unsuitable. Shutter vibrators work by vibrating the forms, which should be sturdy. Shutter vibrations can be used in conjunction with poker vibrators Beam vibrators - These are designed for compacting concrete floors and slabs and in addition to compaction they also help in providing a flat and even surface. COMPACTING CONCRETE Types of Vibrator —&COMPACTING ie) eas Poker vibrators > Use the largest vibrator that will fit between the reinforcement. Always Ensure that you can see the surface. Insert the poker down to the necessary level - it should just penetrate the previously ‘compacted layer below. (There Is litle benefit in Just dragging the poker across the surface.) Avoid touching the formwork or reinforcement. If special or high-quality finishes are required, use rubber against formwork ‘burns’ / Xe Xe X | A. ~ ‘Once ait bubbles stop rising, withdraw the poker and insert it at the next position. Ensure that the vibrated areas overlap. If in doubt vibrate longer. Never use a poker to make concrete flow; this may cause segregation. Short poker heads (300-450 mm) can vibrate a layer depth of 300 mm, no more. Long poker heads (450-600 mm) can be used for depths up to 500 mm.Slabs up to 100 mm thick can be compacted by hand tamping but a vibrating beam will produce a better Job. With heavily reinforced slabs, start compaction with pokers and finish with a vibrating beam. If it becomes necessary for workers to walk or stand on the reinforcement while ‘compacting the concrete, it is essential that the steel is adequately supported by spacers/stools to avoid deformation 10 Ifthe slab is more than 150 mm thick, use a beam vibrator and compact the concrete in layers, edges of slabs should be compacted with poker vibrators. COMPACTING CONCRETE Beam vibrators —&General tips > To ensure that pokers and other vibrators work correctly it is important that they are well maintained and used with adequate safety precautions: * Always double-check the security of connections on air lines before starting work + Always have a standby vibrator and an alternative power-source available * Keep bearings well greased lear moisture out of air lines before connecting to vibrators * Don't leave vibrators in the same spot for too long period * Switch pokers off immediately when withdrawn from concrete + Thoroughly clean all compacting equipment after each pour. "1Plan the work well in advance. Study the drawing for likely trouble sport such as congested reinforcement or built-in items. Use the correct type of concrete - a ‘pump’ mix may be most suitable. Confirm mix suitability with your concrete producer. Ensure that poker hoses and power lines are long enough to reach the place of pour and there is sufficient lighting arrangement to see into forms. Place the concrete uniformly and avoid dropping it from a height. Be prepared to lift the poker out and fe-insert it to avoid tie-bolt positions etc, 12 COMPACTING CONCRETE Walls and columns —&COMPACTING CONCRETE Columns > With small columns, it is easy to feed the concrete faster than it can be compacted, To ensure full compaction, the concrete should not be placed any faster than 300 mm depth every 20 seconds. Concrete delivered by truckmixer and conveyor can be particularly advantageous in these situations. Lower the poker down before depositing up to 300 mm depth of concrete in the first (bottom) layer. It is rarely possible to use more than one vibrator for a column because of restricted space on access platforms. Therefore, when concreting larger columns, it is sensible to use one poker to compact the concrete in layers, slowly withdrawing the poker and te-inserting in the next position to obtain complete compaction.Concrete of less than 25 mm slump can be compacted to give up to a 10° slope. Only the top layer should be sloped, lower layers should be placed horizontally. Spread a length of about 1m toa uniform surcharge of about 20 mm. Then 'work' a temper up the slope. If the concrete slumps after compaction, give it a second pass with the tamper after about an hour. ‘As with slabs, compact edges with a poker to ensure that edges are fully compacter and durable. 14 COMPACTING CONCRETE Concreting on slopes —&COMPACTING CONCRETE Plastic settlement, voids and cold joints > Plastic settlement may occur above reinforcement steel, prestressing ducts and void formers. The primary cause of plastic settlement is excess bleeding and/or rapid early drying conditions. Plastic settlement cracks typically appear over reinforcement, over top of columns (arching action), or at a location where there is sudden change in the depth of section. To prevent the formation of voids, place concrete up to the underside of the ducts, wait around 30 minutes, depending on temperature, and re-vibrate. Then continue placing and compacting. To avoid cold joints in mass concrete, place concrete as shown (left). Do not allow concrete to harden appreciably before it is covered by the next layer and always re-vibrate standing concrete before placing the adjacent fresh concrete, Where void formers are to be surrounded by concrete, small holes should be drilled at regular intervals in the soffit of the former to ensure air escapes. When total volume of concrete to be placed at a time is large, there is a likelihood of a large heat build-up and special measures will be necessary to contain the temperature gradient. A specialist should be consulted for this purpose. 15Look and listen Compaction is generally complete when air bubbles stop rising to the surface and noise of the poker stops changing. A glossy film of mortar on the surface is another good sign, with non air-entrained concretes. Always vibrate a bit longer than you think necessary - except for slabs and high workability mixes, where over-vibration may result in excessive surface laitance. 16 COMPACTING CONCRETE When is compaction complete? —&Re-vibration can be used as long as concrete is still sufficiently workable. ‘The technique can reduce plastic cracking and air voids in the top as 600 mm, producing: COMPACTON (elu aUs) + higher strength + better surface finish \ + enhanced durability. When can I re-vibrate concrete? To assess concrete for re-vibration: Insert a poker - If it sinks in to the concrete and the hole closes when it is removed, the concrete can be re-vibrated. The top 600 mm of columns and walls can normally be re-vibrated about 30-60 minutes after finishing the main compaction. As long as the concrete is still workable, re-vibration can help reduce plastic settlement up to about two hours after main compaction. 7Concrete develops its full potential only when it is efficiently cured and protected from premature drying. Well cured concrete Is stronger, more resistant to chemical attack and traffic wear, and more watertight. Itis also less prone to damage by frost and abrasion. There are two principal ways of curing concrete: 1. Keep the concrete surface wet by ponding, mist spraying or covering with damp sand/damp hessian. Although there may be practical difficulties, these are most effiective methods. Methods of curing 2. Use polythene sheeting, spray curing membranes or leave the formwork in place (not applicable for slabs) to prevent the loss of moisture from the concrete. Whilst not as effective as the first methods, these generally give satisfactory results. 18Hessian and ponding ee The use of hessian, kept damp by regular water spraying, can be an effective methods of curing. As with water ponding, the method is only suitable for use on flat surfaces. This method of curing has the disadvantage that the hessian must be kept wet at all times which entails constant monitoring. Dry areas will do more harm than not curing at all. Therefore, this method of curing should be used only when it can be monitored for 24 hours a day. Ponding of water onto a concrete slab that has lost its initial sheen of bleed water Is perhaps the best method of curing as all the concrete is covered with water. This has the practical disadvantage of being suitable only for slabs, being labour Intensive and requiring a clay bund around the slab perimeter. 19Polythene sheeting should be placed on a slab as soon as the concrete is hard enough to prevent surface damage or marking. Exposed edges and comers should be well fixed down to avoid wind and draughts drying the concrete. When the slab has a special finish - such as texturing - lightweight frames should be used to support the polythene above the concrete. 20 Polythene to columns and beams should be tied with tape or cord. If possible, wet the concrete the day after placing and re-seal the polythene. Polythene sheeting —&Sprayed membranes > Sprayed membranes should generally be applied only to damp - not wet ~ surfaces; otherwise they will be absorbed in to the concrete and cause discolouration. If the surface has dried out, wet the concrete with clean water and apply the spray whilst still moist To ensure even coverage, the membrane should be applied in two perpendicular directions with the head of the spray held about 300 mm from the surface. When spraying slabs it may be necessary to stand on a portable walkway to avoid damaging the concrete surface. Note: Care should be taken when selecting chemical membranes as some types will prevent the adhesion of applied finishes, particularly those used inside buildings. 2A venture of Hathway Investments Pvt. Ltd., RMC Readymix (India) Pvt Ltd. began commercial operations in 1996. Under the guidance of RMC, UK, the world’s largest producer of ready-mixed concrete, RMC India broke new grounds and today possesses the country’s largest installed capacity for commercial ready mixed concrete. As of March 2008, the Company has around 50 networked plants in 20 cities with capacities varying from 60 to 120 m’/hour. RMC India is synonymous with its core product: ready mixed concrete. The Company follows best international standards and practices in delivering quality products to its customers. The quality assurance procedures practiced by RMC Readymix are based on United Kingdom's QSRMC (Quality Scheme for ready Mixed Concrete). In fact, the Company was the first and still the only manufacturer in India to implement the CUSUM method to ensure batch-wise consistency in concrete quality. In keeping with its pioneering role, RMC Readymix has successfully developed and introduced a wide range of special products such as Fibre Reinforced Concrete, Coloured Concrete, High-Performance Concrete, Self-Compacting Concrates, Temperature-controlled Concrete, etc. 2 Dial aaa REVOLUTION‘Ahmedabad Block No. 140, Sante) Vadsar Ra, Village Sante), Taluka Kalo, Dist, Gandhinagar. Ahmedabad, “Tel 02764:323868 Ghaziabad Plot no, 865, Ind. Area Site 4 Sahibabad, Ghaziabad, 201010, Untar Pradesh Tel 01202897688 Jaipur E149 & E1498, Road No. 9), \Vishwakarma industeal Area Jatpur = 302 08. Tel. ovat - 2332283 Mohali Plot No. C107 Phase ~ Vil SAS Nagar, Mohall Punjab ~ 160 055, Tel 0172 2236239 ‘West Bengal Tauri No. 173, Mouza Vilage Podra'700135. District ~ 24. Pargans (North) Tel : 03216-27210), 033-65440806 shnupur, ee RMC Readymix (India) (A Division of Prism Cement Limited) Mix With The Best For further information contact: Head Office: Windsor, 7th Floor, CST Road, Near Vidyanagari, Kalina, Santacruz (East), Mumbal-400 098. Tel: 022-26547000 Bangalore No. 4, 100 ft. Road, 8th Main IV Block Koramangla Bangalore ~ 560 034 Tel :080-25631084/85/86 Goa Survey No. 21/22, Chougule Indl Estate Sancoate Village, Goa - 403 726 Tel: 0832 ~ 6480584 Manipal Plot No. 26, shivaly Indl Area, Opp. Udaya Aluminium, Manipal 576108 Te. 0820-2572828/2572839 ‘Mumbal (H.0.) Windsor, th Floor, CS.:Road, Near Vidvanagar! Kalina, Santacruz (E), Mimbal 400 088 Tel 022-26547000 Surat Plot no. A,14/1, Ichhapore, Bhatpore Estate, surat’ 395010 Tel o261-2840284/248 chennai AC26, SIDCO Industrial Estate, Thirumudivkkam, Chennai - 600 044 Tel: 044 24780868 Gurgaon jo Destam, NrAjantaa St. secondary School, Faroog Nagar, Gurgaon 122001 Tel: 0124-2015978 Lucknow Plot no. E1 & £2, UP SIDC ind Area,Deva ka, ‘hint, Lucknow 226019 Tel: 0522-2818667 Mysore Gonfosyss Technologist, Sysore campus, Hoot all. it no 380- 525, edbal econ Cy, Teh: 0ea 3070 Vishakapattnam Plot A, BBlock, Assisted PML In Estate, Auto Nagar, Vishakapattnam, Andra Pradesh 550012, Tel 0891-2701342 Coimbatore Survey No. 2568 258, Kannampalayam Vilage Tichy Rd, Coimbatore. Tel = 0422.2680085/50 Hyderabad Unit 4A, Nacharam ind. Area, Hyderabad ~ 500076. Tel: 04027159132 Mangalore Poco. 38 Bykampady I. zea ‘yeampady Vilage, Sura Ho, ‘Mangalore Talks Dakshina. kannada (Dis, Mangalore Tels zen0a6/97, Pune Survey No. 97/1, Plot no. 123-124, am Tekdl Indl. Area, Hadapsar, Pune ~ 411 028, Tel: 952056224415, 32540075,