CONCRETING

The ready-mix/batching plant

Most concrete is batched and mixed in a central location called a ready-mix plant and then

trucked to the desired location. This is often the best solution even for fairly small jobs. Ready-

mix plants have a wide variety of aggregate and cement that are stored under controlled

conditions, as well as good equipment for weighing and mixing. As a result, the quality of the

concrete should be high and consistent. Concrete mixing trucks can be used to transport

already-mixed concrete, or the mixing can actually be performed by the truck as it is traveling

to the site. One potential disadvantage of ready-mixed concrete is that the time required to

transport the concrete to the site may use up too much of the early period of good workability.

This can generally be handled through the use of retarding admixtures.

Placing

Once the concrete has been

adequately mixed, it must be placed into the

formwork that defines its final position and

shape. If the concrete is to be reinforced, the

rebar must already be in place so the

concrete can flow around it.

If the concrete mixing truck can be

located close to and higher than the site,

then the concrete can be poured directly

into the forms. In cases where this is not

possible, the concrete can be transferred in

buckets by a crane or by wheelbarrow.

Concreting using crane and bucket.

 When this is impractical due to the distance required or the size of the job, the fresh

concrete can be pumped through a system of pipes or hoses to the site by special concrete

pumps. Concrete that is to be pumped has more stringent requirements for workability. If the

concrete is too dry, it will not pump well, while if it is too wet it will tend to segregate.

Segregation can also occur if the concrete falls into the formwork too quickly, as larger

aggregate particles will tend to be driven downward.

Concrete pump for placing concrete.

Consolidation

Once the concrete is in place, it should be consolidated to remove large air voids

developed during placement and to make sure that the concrete has flowed into all of the

corners and nooks of the formwork. This process is also called compacting. Over consolidation

can lead to segregation and bleeding, but under consolidation is more common, resulting in

less-than optimal properties. The two most common methods of consolidation is are vibration

and roller compacting. Vibration is a mechanical process that transfers pulses of shear energy

to the concrete, usually by a probe that is inserted several inches into the concrete. Each pulse

of shear energy momentarily liquefies the concrete, allowing it to flow very freely. This is the

standard consolidating method for general construction projects with the exception of roads.

The shear energy will only travel through a limited thickness of concrete, so when a thick

concrete structures is being placed the fresh concrete is poured in layers, with each layer

consolidated before the next is poured over it. Vibration is a noisy and labor-intensive step,

requiring expensive and specialized equipment.

Finishing

For concrete floors and pavements, the appearance, smoothness, and durability of the

surface is particularly important. Finishing refers to any final treatment of the concrete surface

after it has been consolidated to achieve the desired properties. This can be as simple as

pushing a wide blade over the fresh concrete surface to make it flat. Floating and troweling is a

process of compacting and smoothing the surface which is performed as the concrete is starting

to harden.

Power trowel is used to apply a smooth finish on concrete slabs.

Curing

Burlap sack used for curing concrete.

Once concrete has been placed and consolidated it must be allowed to cure properly to

develop good final properties. As the concrete hardens and gains strength it becomes less and

less vulnerable, so the critical time period is the first hours and days after it is placed. Proper

curing of concrete generally comes down to two factors, keeping it moist and keeping it

supported. Hydration of cement, as the word itself implies, involves reaction with water. To

cure properly, the cement paste must be fully saturated with water. If the relative humidity

level inside the concrete drops to near 90% the hydration reactions will slow, and by 80% they

will stop altogether. Not only will this prevent the concrete from gaining its full strength, but it
will also generate internal stresses that can cause cracking. To keep fresh and young concrete

moist, it can be covered with plastic or damp fabric to prevent evaporation, or sprayed

periodically with water.

The weather plays an important role in the curing process. Hot windy weather leads to rapid

evaporation and thus particular care must be taken to keep the concrete moist. Cold weather

causes the concrete to harden much more slowly than hot weather. This delays the

construction process, but leads to better concrete in the long run, because the hydration

products develop differently at different temperatures. If fresh concrete freezes, however, it

will likely be destroyed beyond repair.