DOS AND DONTS IN SITE ACTIVITIES

OF CONCRETE WORKS

Workability of Concrete
IS:456IS:456-2000
Concrete mix proportions chosen should be such that the concrete is of adequate workability for the placing conditions of concrete and for proper compaction with the means available Note : For most placing conditions, internal vibrators are suitable. The diameter of the needle based on the density & spacing of reinforcement and member thickness. For tremie concrete vibrators are not used.

Compaction of Concrete
How to Vibrate ?


Spread the concrete uniformly in layers not more than 300 to 500 mm depth Do not move the concrete sideways using poker Vibrate systematically, inserting the vibrator vertically at intervals equal to 8 to 10 times the diameter of the tube Push the poker about 150 mm into the previous layer to obtain maximum adhesion

Compaction of Concrete
How to Vibrate ?


In forms with sloping floors, first fill with concrete to make a level surface and then start vibrating at the deepest part Push the poker straight down. When vibrating concrete floor slabs, insert at an angle to improve contact between concrete and tube. Concrete is thoroughly vibrated when the surface round the poker goes glossy and no more large bubbles appear (normally it takes 10-20 seconds) 10-

Improper Handling Technique s of Internal Vibrators

Improper Handling Techniques of Internal Vibrators

Improper Handling Techniques of Internal Vibrators

Compaction of Concrete
Method of Poker Insertion

Compaction of Concrete
Method of Compaction

Lapped bars can create problems

Concrete must be placed. Where bars are lapped check their thickness and spacing

Leave room for vibration ! *!?!----- after all Ive said !

Ties and bracings for Lateral Stability



Vertical loads transmitted to base by tubes. Ties should be of push/pull type Ties, bracings should be in position as specified. specified. Continuous diagonal bracing tubes should be connected to every node point. point. For nominal loads, provide one diagonal bracing for six rectangular forms by the vertical tubes. tubes. For heavy loads and wind force, the number of bracings should be calculated and provided for. for.

 

Brace couplers

Diagonal bracing layout

Foundation for scaffolds



Scaffolds require foundation to support without undesirable deformation. Load in tube is transmitted through a plain or adjustable base to foundation or spreader of timber, conc or steel. Design of foundation supports for scaffold pipes resting on river bed and in water requires special attention. Traditionally timber ballies (150(150200mm dia.) are driven to refusal and brazed at top, above water level to receive the scaffolding system.

Deshuttering of formwork Vertical forms



Vertical formwork to be in position until concrete stiffens sufficiently to sustain itself i.e. final setting time of concrete (4-6 hrs) (4Increased time before deshuttering results in reduced number of re-uses without any technical rebenefit; also hinders commencement of curing. Steel formwork absorbs solar heat, leading to fast evaporation of water from concrete, leaving insufficient water for hydration.

Deshuttering Construction joints



Formwork of vertical construction joints should be removed within 2-3 hrs of concreting to 2ensure removal of cement mortar laitance and expose aggregates before final setting of concrete. It should never be left for more than 12 hrs If the formwork is to be left for longer period, the face of formwork in contact with concrete should be coated with a surface retarder to facilitate treatment of concrete surface

Workmanship Concreting


Concreting by experienced gangs. 2 level control. Method of control by pour card recommended.

Placing and compacting under supervision. Regular control by qualified staff, surveillance by QA team.

Proper curing checked by independent supervisors and documented

Spotting the pump



Position pump so that pipelines are short and straight and do not need repositioning often. Keep room for 2 concrete trucks at pump hopper When there is no room for 2 trucks, alternate arrangement should be made like fixing a chute or using one front-discharge and other rearfrontreardischarge concrete trucks. Set truck mounted placing booms on level ground

 

Concrete Placement by Pumps Locating The Pump



Position the pump close to the concreting location. For safe operation, the truck pump should not be too close to a open excavation Provide locked storage area for standby equip, replacement parts, extra hose and line sections Prepare a scale drawing of the job site, pumps and TMs to plan best arrangement If not possible to provide access to both sides of pump hopper due to congested location, a chute can be provided for unloading the second truck

Pipeline
  

All pipelines should be laid either vertically or horizontally but never inclined. Pipe diameter varies from 100 to 200mm. Resistance due to velocity of flow is more than volume of concrete being moved; for horizontal surfaces higher dia pipes can be used, for high rise pumping smaller dia pipes are recommended. During concreting, pipes should never be added, but broken back towards the pump, starting at the farthest point first and finishing close to pump.

Correct support

Defective support of concrete pipeline

Pumping of Concrete Lubricating Mix



For lubricating a pipeline, lubricating mix pumped immediately before the first regular concrete mix It consists of two parts of cement one part of sand and water. ( used for > 100 m pipeline) The consistency of the mix should be soft For short pipelines lorry mounted concrete pumps with placing booms cement & water used Quantity of lubricating mix depends on length and diameter of the pipeline

 

Site Management for Pumping

  

 

Small pours should be discouraged. Large volumes should be pumped continuously. Keep many locations ready for concrete at a time. Pumping only in daylight barring exceptions. Pours to start early. Smaller pours may be started later but should be completed before sunset. Arrange for checking of concrete slump regularly. Concrete delivered to pump must be of consistent quality throughout period of pumping.

Pumped Concrete- Blockages Concrete

Unsuitable concrete mix

 Slump below 50 mm  Slump above 150 mm  Inadequate fines  Cement other than OPC

  

Sudden starts, stops Too long a line Getting air into the system No mix in the hopper Inadequate conc pressure Grout leaking joints Absence of initial lubricating mortar

 

Change in c/s of pipeline Over size agg particles Sharp Bends in pipeline

 

Pumping of Concrete Maintaining the Pump & Pipeline



The concrete pipeline should be visually inspected for damage each day Pipeline wall thickness shall be tested using ultrasonic thickness gauge Pipeline that has become worn must be replaced when its safe working pressure falls below the pressure capacity of the concrete pump

Large volume pumping Aspects to be checked

      

Sequence and speed of placing concrete Pump locations and movements Adequate provision of pipes and fittings Access to pumps for two or more trucks Water, compressed air and grout Control of concrete production A controller to regulate truck movement by proper communication with pump and truck drivers Floodlighting for night work.

Training of pump operators

       

Basics of concrete, requirements for pumpability Operating and maintaining pumps and vehicles Boom operation Rigging pipelines Concrete placing Rectifying concrete blockages Cleaning and inspecting equipment Safety

Contract Planning


Check contract docs, drawings, quantities, site access, services, working space, material source, Technical information : concrete, grade, cement, aggregate, admixtures, w/c, workability, testing, reinforcement, formwork, temp/ancillary works Planning : Management plan, site layout, temporary/supporting works, test schedule, labour requirements, daily concrete demand