T. A. H. Miller

“ All grains, small pebbles, or particles of broken stone are considered as sand if they will pass through a wire screen with one-fourth inch meshes. The particles or grains should be hard and well graded and should vary in size, as a stronger concrete is thus obtained than when the size of the grains is nearly uniform. If a large proportion of the sand is very fine an extra quantity of cement should be used and if exceptionally fine it is advisable to use 25 per cent more cement. ”

“ The maxim that a chain is only as strong as its weakest link applies to concrete. If the coarse aggregate is weaker than the cement mortar, as in the case of some sandstones, it should be used with caution. The aggregate may have properties that render it unsuitable for use under certain conditions; for instance, cinders should not be used if water-tightness or strength is expected, but they are useful for fireproofing. Material that disintegrates or flakes when heated is undesirable in places exposed to high temperature ”

“ A 1:2:4 concrete will prove practically impermeable in ordinary construction, but if a head or pressure of water is to be resisted a 1:2:3 or richer mixture may be necessary. The consistency is very important. A sluggishly flowing consistency is best, for if the concrete is too wet the mortar may flow away from the stone, leaving leaky places and, if too dry, the mass may prove porous. The proportions and consistency must be accurately maintained for each batch and the concrete must be exceptionally well mixed.
It is necessary to exercise great care in the placing of the concrete. ”

“ The number of men required is determined by the amount of concrete to be placed in a given time, the method of mixing, and the size of the batch; that is, the number of bags of cement mixed at one time. The amount of concrete one man can mix by hand in a day depends upon the experience of the man, the layout of the work, and other duties required of him. One man should average 11/2 to 13/4 cubic yards of concrete in eight hours, including mixing and wheeling not more than 50 feet. ”

“ A number of brands of Portland cement are manufactured, most of which are made to meet the requirements of a fixed standard adopted by the United States Government and the American Society for Testing Materials. Cement always should be tested for use in important work, but this is impractical for the user of small amounts and it is generally safe practice to omit the test if a reliable brand of Portland cement of American manufacture is selected, especially if the dealer's or manufacturer's guaranty that it meets the standard is secured. ”

“ Broken terra cotta, brick, and old concrete, if hard and strong, may be used for unimportant work where no great strength is required, but special care should be taken that the particles do not show on the finished surface. ”

“ Fresh concrete will riot bond readily to concrete that has hardened and a seam may be formed that will permit water to trickle through. When bonding fresh concrete to that which has been in place for a short time it is usually sufficient to roughen the hardened surface with a pick or by other means so as to expose the gravel or stone, and to clean off all loose particles. The hardened concrete should be soaked with water, the excess water removed, and the surface then given a coat of grout (a mixture of cement and water) of the consistency of cream just before the new concrete is deposited. ”

“ A one-bag batch machine is most suitable for general work, though there are smaller mixers that may prove handy. Some of the smallest sizes are operated by hand, but the medium and large sizes are power operated. Mixers can be had with or without the power plant attached and may be stationary or on wheels, which facilitate moving to different sites. Engines used for sawing wood, the larger ones used for pumping water, and tractors furnish sufficient power to operate an average mixer. Figure 7 shows a homemade mixer built of discarded farm implement parts and operated by the farm engine. ”

“ Concrete, while plastic, exerts a great pressure on the confining walls, necessitating rigid tying and bracing of the forms to keep them from bulging out of alignment. The effect of the bulging of a form is corrected only at a considerable expense; hence it is advisable to pour the concrete to a depth of not more than 21/2 or 3 feet, allowing it to set or harden before pouring more. ”

“ Before starting to mix, annoyance and money may be saved by planning the location of the mixing plant with regard to convenience in depositing the concrete in the forms and ease of access to the materials. Often the board can be located so that by moving « 14 » it once or twice the bulk of the concrete may be shoveled directly into the forms. It is more economical to wheel material a distance of from 10 to 25 feet than to carry it in shovels. Eight feet is about as far as it is profitable to shovel. ”

“ More concrete can be made from given volumes of aggregates if the gravel used is graded from fine to coarse than if the particles are too nearly of one size, because the small stones help to fill the voids between the larger ones and less sand-cement mortar is required. ”

“ Too of ten the finishing of the concrete work in even the more important farm buildings is neglected. With little extra trouble exposed surfaces can be given a finish which will add to the attractiveness and hence the value of the completed work. Rubbing off the form marks and pointing up depressions or holes greatly improves the appearance of the work. The rubbing may be done with a wooden float or hard-burned brick, using a little sand and water as an abrasive and a 1:2 mortar for pointing up. ”

“ Concrete expands and contracts with changes in temperature, causing cracks to appear. Contraction cracks occur in thin sections exposed to wide variations in temperature and are common in sidewalks; therefore, large stretches of concrete should not be laid without breaks or spaces to allow for the changes in size. The spaces should be filled with tar or some similar material that will yield or give when the concrete expands. ”

“ The materials then should be turned over in much the same manner as was the sand-cement, except that instead of shaking them off the end of the shovel the whole load should be dumped and dragged back toward the mixer with the square end of the shovel. The wet gravel picks up the sand and cement as it rolls over when dragged back. The mixing should be continued until the mass is uniform, water being added to the dry spots during the mixing until the desired consistency is obtained.
Experience counts considerably in mixing concrete with the least amount of labor ”

“ Perhaps the most satisfactory method of preventing freezing of concrete is to heat the materials and to inclose or cover the completed work for a few days or until most of the water has disappeared and sufficient strength has developed. ”

“ When the weather is cold but not freezing, heating the materials will be sufficient. If a freeze is expected the concrete work should be protected by wood inclosures, paper, or canvas, over which, if the surface is horizontal, may be spread a 6 or 8 inch layer of straw. Manure should not be used to protect fresh concrete, since the acids in it are destructive and cause unsightly stains. ”

“ Although such gravel occasionally contains nearly the right proportions of sand and gravel, in the majority of sand pits and gravel banks there is a great variation in the sizes of the grains and pebbles or gravel and in the relative quantity of each. It is advisable to screen the sand and gravel and to remix them in the correct proportions, as well-graded aggregates make stronger concrete and, ordinarily, enough cement will be saved to pay for the cost of screening. ”

“ The mass should be turned two or three times, or until it is of uniform color and there are no streaks of either sand or cement. A man with a hoe or rake may assist by raking the top over as the two men turn. When the sand-cement mixture is of a uniform color it should be spread out carefully in a layer and the gravel box placed on top. The box is filled with gravel and then removed, the gravel being spread over the sand-cement mixture. The mass is soaked with about one-half the quantity of water to be used, care being taken not to wash away any of the cement. ”

“ The concrete should be deposited in horizontal layers, preferably not over 6 inches thick, and a spade or paddle should be worked up and down against the forms to push the coarse material away from the surface, as illustrated in Figure 13. The object of the spading is to eliminate impounded air that may form pockets in the mass and to insure a smoother and more « 20 » impervious surface. In addition to being spaded, stiff concrete should be rammed until water flushes to the surface. Tapping the forms with a hammer is a very effective way of securing a smooth surface. ”

“ However, the extra cost at times may be warranted by urgent need of the structure or the fact that other farm work is not so pressing during the winter and the concrete work may be carried on without seriously interfering with regular farm operations.
Concrete must be protected from alternate freezing and thawing until it has set. Cold retards the setting and hardening of concrete; therefore, even though the temperature is not at the freezing point, the concrete should be protected and special care taken not to subject it to loads. ”

“ A pleasing finish can be secured by scrubbing the surface with a stiff fiber or wire brush, using plenty of water to wash off the loosened particles. The work must be done while the surface is workable for if the concrete is too green or soft the aggregate will break out and if too hard the work can not be done effectively. ”

“ T THE successful and economical use of concrete involves the selection of suitable materials, the correct proportioning of mixtures in the development of qualities to meet specific requirements, the proper placing and the care of the green concrete.
A concrete of great strength is uneconomical if a weaker mixture will serve and a cheap or weak concrete is costly if it does not fulfill all requirements. ”

“ If more than 3 feet of concrete is poured at one time the ties should be closer together, vertically, at the bottom of each pouring. The thickness of the wall does not affect the number of ties. On removing the forms the wires should be clipped close to the face of the concrete and punched back, unless the surface is to be stuccoed. If a pit hole is caused by punching back the wire it should be pointed up with mortar, which then should be rubbed to make it blend with the general surface. ”

“ Lava rock varies widely in chemical composition and physical qualities. In some instances lavas are so light and frothy or contain so large a proportion of easily oxidizable material that they are wholly unsuited for concrete work. ”

“ Cinder concrete, on account of its light weight, commonly is used for filling between sleepers of floors and grading roofs, and frequently for fireproofing, for which it is very effective. Cinders should never be used when the concrete is to be subjected to heavy loads or abrasion. ”

“ The larger particles used in concrete may be gravel, broken stone, air-cooled blast-furnace slag, or other suitable materials. The coarse aggregate should be sound and clean, that is, free from disintegrated or soft particles, loam, clay, or vegetable matter. Air-cooled blast-furnace slag should weigh at least 70 pounds per cubic foot. ”

“ Make a ball, about 11/2 inches in diameter, if neat cement and water; place it under a wet cloth and keep it moist for 24 hours, then put the ball in a vessel of water; allow the water to come to the boiling point slowly and to boil for 3 hours. A good cement will not be affected, but an inferior one will check, crack, or go to pieces entirely.
Portland cement is shipped in paper bags, cloth sacks, and wooden barrels (sometimes in bulk) . For the average user the cloth sack is the best container, as it is easier to handle ”

“ Practical water-tightness in concrete may be secured by using a fairly rich mixture properly proportioned. Foreign ingredients, membrane and surface coatings, or other means need not be used, except where poor workmanship is likely or where considerable damage and inconvenience may result in case of leakage. ”

“ A lintel is a beam, and when a beam bends the lower part is stretched or pulled while the upper portion is compressed. Good concrete will stand great pressure but is not capable of resisting any great pulling or tensile stress. ”

“ If a handful is squeezed it will retain its shape. This consistency requires thorough ramming to eliminate voids and is used when forms are to be removed immediately, but should not be used where a water-tight job is expected. The porous structure of the concrete in Figure 2 is due to the fact that it was placed as a dry mixture. ”

“ When material is to be wheeled, runways of planks should be provided, because more material can be handled in a given time, and the wear and tear on men and equipment is not so great. The planks used in the runways should be thick enough to sustain the weight passing over them and should be 10 to 12 inches wide to permit foot room. ”