1. 1.0 Introduction:-
• Few things are more aggravating to produce on a worksite than concrete. Bags of cement,
sand, aggregate (gravel) and possibly other additives must be delivered to the construction
area. A supply of clean water is also necessary, along with a rented concrete mixing hopper.
• Even after all the dusty and heavy ingredients have been loaded into the hopper, one small
error in the wet/dry ratio can render an entire batch of concrete unusable. One common
solution to this messy and time-consuming problem is “READY MIX CONCRETE”
• Ready-mix concrete (RMC) is a ready-to-use material, with predetermined mixture of
cement, sand, aggregates and water. RMC is a type of concrete manufactured in a factory
according to a set recipe or as per specifications of the customer, at a centrally located
batching plant.
• It is delivered to a worksite, often in truck mixers capable of mixing the ingredients of the
concrete en route or just before delivery of the batch.
• This results in a precise mixture, allowing specialty concrete mixtures to be developed and
implemented on construction sites.
• The second option available is to mix the concrete at the batching plant and deliver the mixed
concrete to the site in an agitator truck, which keeps the mixed concrete in correct form. In
the case of the centrally mixed type, the drum carrying the concrete revolves slowly so as to
prevent the mixed concrete from "segregation" and prevent its stiffening due to initial set.
• The use of the RMC is facilitated through a truck-mounted 'boom placer' that can pump the
product for ready use at multi-storied construction sites. A boom placer can pump the
concrete up 80 meters.
• RMC is preferred to on-site concrete mixing because of the precision of the mixture and
reduced worksite confusion. It facilitates speedy construction through programmed delivery
at site and mechanized operation with consequent economy.
• It also decreases labour, site supervising cost and project time, resulting in savings. Proper
control and economy in use of raw material results in saving of natural resources. It assures
consistent quality through accurate computerized control of aggregates and water as per mix
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2. designs. It minimizes cement wastage due to bulk handling and there is no dust problem and
therefore, pollution-free.
• Ready mix concrete is usually ordered in units of cubic yards or meters. It must remain in
motion until it is ready to be poured, or the cement may begin to solidify. The ready mix
concrete is generally released from the hopper in a relatively steady stream through a trough
system. Workers use shovels and hoes to push the concrete into place.
• Some projects may require more than one production run of ready mix concrete, so more
trucks may arrive as needed or additional batches may be produced offsite and delivered.
• However there are some disadvantages of RMC to, like double handling, which results in
additional cost and losses in weight, requirement of god owns for storage of cement and large
area at site for storage of raw materials.
• Aggregates get mixed and impurities creep in because of wind, weather and mishandling at
site. Improper mixing at site, as there is ineffective control and intangible cost associated
with unorganized preparation at site are other drawbacks of RMC.
• There are always possibilities of manipulation; manual error and mischief as concreting are
done at the mercy of gangs, who manipulate the concrete mixes and water cement ratio.
• The first ready-mix factory, which was built in the 1930s, remained in a standstill position till
1960s, but continued to grow since then.
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3. 2.0 History:-
• Ready mix concrete was first patented in Germany in 1903; its commercial delivery was
not possible due to lack of transportation needs.
• The first commercial delivery was made in Baltimore USA in 1913.The first revolving
drum type transit mixer was developed in 1926. In 1931, a RMC plant was set up for the
construction of Heathrow airport, London.
• In the mid 90’s there were about 1100 RMC plants in UK consuming about 45% of
cement produced in that country. In Europe in 1997 there were 5850 companies
producing a total of 305 million cusecs of RMC. In USA by 1990, around 72% (more
than 2/3rd) of cement produced was being used by various RMC plants. In Japan first
RMC plant was set up in 1949. By 1992 Japan was the then largest producer of RMC,
producing 18196 million tons of concrete. In many other countries of the world including
some of the developing countries like Taiwan, Malaysia etc, RMC industry is well
developed.
Development in India
• In India RMC was first initially was used in 1950 during the construction sites of Dams
like likeBhakraNangal, Koyna. At the construction the transportation of concrete is done
by either manually or mechanically using ropeways &buckets or conveyor systems. RMC
at Pune in the year 1991. However, due to various pit falls and problems this plant did not
survive for long and was closed. Within a couple of months in the year 1993, two RMC
plants were set up in Mumbai to commercially sell RMC to the projects where they were
installed. Unitech Construction set up one plant at Hiranandani Complex and Associated
Cement Companies set up another plant at Bharat Diamond Bourse Commercial
Complex.
• The first concrete mixed off site and delivered to a construction site was effectively done
in Baltimore, United States in 1913 just before the First World War.
• The increasing availability of special transport vehicles, supplied by the new and fast -
growing automobile industry, played a positive role in the development of RMC industry.
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4. 3.0 Scope of Ready Mixed Concrete Plant:-
• Long, Long years ago, their where simple houses but in 21st century we can see houses
constructed in R.C.C.
• Therefore concrete got more importance than any other construction material. So the use
of concrete is increasing day by day.
• For construction most of the contractors and builders have to collect the raw materials
required for the construction before starting actual works. These materials should be
stored at the site properly. This technique can be possible when there will be more empty
space at the construction site which is not possible in congested areas. At this time there
is one solution to overcome all these problems that is nothing “READYMIX
CONCRETE”.
By using R.M.C we can save time and money required for the labours. In
following places ready mix concrete can be used:-
1. Major concerting projects like dams, roads, bridges, tunnels, canals etc.
2. for concreting in congested areas where storage of materials is not possible.
3. Sites where intensity of traffic makes problems.
4. When supervisor and labour staff is less.
5. To reduce the time required for construction etc.
6. Huge industrial and residential projects.
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5. 4.0 Details of Plant Visited Site:-
• Address of the Plant Visited Site: -
Innovative Infrastructure, Ready mixed concrete,
Opp. Ekta Hotel,
Sarkhej, Ahmedabad.
Location: -
Key Plan
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6. • Time of Establishment: - 02/06/2006
• Authority People: -
(1) Mr. Harishbhai Gohil
(2) Mr. Natubhai Gohil
• Area of Plant: - Minimum area is 3500 yard
• Timing: - 24 hours working
• Human Resource Management: -
Workers 36
Engineers 20
Total 56
Financial Aspect:-
• Investment Cost: - About 8 to 9 Crore
1 Crore Plant 75 lakh batching Plant
25 lakh silos
36 lakh of Trucks 1 Truck x 22 times
4.5 Crore of Land
• Maintenance Cost: - 65 rs/ m3
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7. • Charges to the Clients: -
Grade Rate/ m3
M 7.5 2600 rs/m3
M 10 2900 rs/m3
M 15 3500 rs/m3
M 20 4000 rs/m3
M 25 4300 rs/m3
M 30 5000 rs/m3
• Recent Project:-
Project name
• Tesla Pronestyl, Shantipura Choki
• Per Day 200 m3 Concrete Supplied
• About 5 km from Plant
• Cost of Raw Material:-
Material Rate/tonne From
Sand 224 rs/tonne Sabarmati
Aggregate 700-740 rs/tonne Surendranagar
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8. 5.0 Flow Chart of Manufacturing Process:-
• Inert raw material namely fine aggregate and coarse aggregate are stored in bins, where
as cement is stored in hopper.
• Water and admixtures are stored in tanks. The inert raw materials are fed to the batching
plant mixer by means of an aggregate belt conveyor.
• The required quantity cement is extracted by screw conveyor and fed into the mixer.
• Water and admixture are pumped into the mixer bye weight. After the mixing is
completed, the ready mixed concrete is discharges into the transit mixer which can then
transport the concrete to the construction site.
• All these above operation are controlled by a computer housed in the control room of the
batching plant.
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9. Manufacturing process of Concrete in R.M.C. Plant
Raw Material used to produce Concrete
• Ready-mix concrete is made from cement, aggregate and water.
• Aggregate make up majority of the concrete’s volume and the cement provides resistance.
• Additives are incorporated into the mix to ensure particular properties such as improved
durability or shortened hardening times.
• During the mixing phase, we control every step to ensure quality and uniformity.
Raw Materials are:-
1. Water
2. Additives
3. Cement
4. Aggregate
5. Air
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10. Aggregates
• Aggregates, which make up roughly 60% to 75% of ready mix concrete’s volume, are
obtained from quarries and aggregate banks.
Additives
• Additives are solid or liquid chemical substance that can be added to ready mix concrete
before or during preparation.
• Most commonly used additives either improve a hardened concrete’s durability or reduce a
concrete’s water content in an effort to shorten setting times.
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11. Water
• This is the mix’s vital fluid sets off a chemical reaction when it comes into contact with
the cement.
Cement
• No others material rivals cement’s important in the mix; it’s the ingredient that gives
concrete its strength.
• The most widely used cements are gray Portland type 1 and Pozzolona Portland type 2.
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12. Concrete mixing
• During the mixing phase, the different components come together to produce a uniform
mass of concrete.
• Mixing time is registered from the movement material and water is poured into the cement
mixer, and it begins rotating.
Ready to use for site
• While transporting concrete to a site, the cement mixer never stops revolving at a speed of
two to six rotations per minute.
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13. 6.0 Equipment Required in R. M. C.:-
Following are the equipment’s required in R.M.C
1. Batching plant
2. Silos
3. Belt Conveyor
4. Transit mixer
BATCHING
Batching plants are classified as
1. Manual
2. Semiautomatic
3. Fully automatic
Storage
Storage of the raw materials is done by following methods: -
Inline Bins
Inert raw materials like fine & coarse aggregates are stored in bins called as “Inline Bins” where
the trucks carrying fine & coarse aggregate can dump the material easily. The aggregates
required are fed by the means of aggregate belt conveyer. On the aggregate belt conveyer the
aggregates are weighed automatically by means of computer form the computer room presents
on the plant.
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14. Batching plants are classified as:-
1. Manual Batching Plant:-
Place of Origin China (Mainland)
Model Number HZS50
Motor Power 5.5kw
Mixing Power 37kw
Charging Capacity 1000L
Speed of Mixing Drum 28r/min
Water Supply Mode Automatic
Working Cycle Period 72s
Discharge Way manual
Outline Dimension 22.2m x 2.4m
Production 50m3/h
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15. Conveyor Capacity 400 t/h
• Mixer
Type JSJ1000
Power 2×18.5 KW
Output 1 m3
Grain Size ≤60 mm
• Batcher
Hopper Capacity 13 m3
Hopper Quantity 3
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16. 2. Semiautomatic Batching Plant:-
• Specifications
Concrete stirring station, our leading product, is formed by semiautomatic concrete
manufacturing equipment
Place of Origin China (Mainland)
Model Number HZS150
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17. • Complete Plant
Peak Capacity 150 m³/h
Cycle Time 60 s
Dimension 43.5 X 24 X 18.7 m
Installed Gross Capacity 260 KW
Standard Discharge Altitude 4m
• Batching Part
Model JS3000
• Feeding Part
Model PLD4800
• Pneumatic System
Air Compressor Model 1.8-7
Rated Air Discharge Rate 1.67
Power of Motor 15 KW
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18. 3. Automatic Batching Plant:-
Place of Origin China (Mainland)
Model Number HZS90
• Specifications
Capacity 90m3/h
Mixing system win-shaft concrete mixer
Aggregate feeder Belt conveyor
Discharging height 3900mm
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19. • Batching Plant
Discharging volume 1500L
Charging volume 2250L
Mixing cycle 60s
Max. mixing size Φ100/80mm
• Aggregate batching machine
Storage bins quantity 4 sorts
Aggregate scale hopper 2400L
Aggregate feeding to mixer by Belt conveyor
• Cement storage and feeding system
Cement silo capacity 60t/80t/100t
Screw conveyor diameter Φ273mm
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20. Storage Silos:-
• The requirements of construction, engineering and process industries come up with an
exclusive range of Cement, Fly ash, Limestone Silos that is manufacture from very high
quality Structural raw material.
• Storage of Cement, Fly ash, Limestone silos are available in 3200mm to 3700mm
diameter and in the capacities of 50, 100, 200 and 300 tons.
• These silos are manufactured in customized specifications as per our client needs and
requirements.
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21. Technical Specifications of Silos
1. Size - 3200mm Dia x 14 mts of Total Height.
2. Side shell thickness - 5mm/6mm thick of sail / VSP/ SSP / Standard make of M.S plate.
3. Bottom cone - 6mm/8mm /10mm thick of above make as per customer requirements.
4. Safety handrail on top will be provided.
5. Maintenance ladder with safety gage provided from bottom to top.
6. Bottom leg pipe should be ERW / Seamless type of TATA / JINDAL Make Of heavy
duty type.
7. Total silo should be two coat Red Oxide & Two coat finish enamel paint or sand blasting
as per customer’s requirements with Asian paints or Berger make etc.
8. Provision will be provided for fixing of silo accessories.
9. Pipe line fittings will be provided with flanges for easy dismantling.
10. Double structure platform will be provided for fly ash storage solos.
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22. Aggregate Feeding Belt Conveyors:-
• Manufactured and Supplied high quality Aggregate Feeding Belt Conveyors for Handling
Sand, Jally, Stones (Aggregates) to RMC batching Plant.
• Capacities from 18 M3 to 300 M3 of various types like Compartment, In Line Silo, Four
Bin Type, Mobile etc.
• Products are made by using very high quality Structural raw material make of VSP, SSP,
TATA, JINDAL STEELS; standard suppliers make for drive unit, Belt etc.
• Also providing Heavy Duty Rollers & Pulleys which ensures hassle free and long life
work performance.
• These Aggregate Feeding Belt Conveyors are widely available in various specifications
and dimensions like 650 MM to 1200 MM wide.
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23. • Ready-mix Concrete Portable Conveyors
• For handling Ready Mix Concrete Output from batching plant to Transit Mixer / Outer Area
with stationary or Portable special Type Belt Conveyors.
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24. Transit Mixer:-
• Specifications of Mixer
Nominal Capacity 6 m3
Geometric Volume 11700 liters
Waterline Volume 7100 liters
Filling Ratio 51.3%
Rotation Speed 0-14 rpm
Length of Mixer 5743 mm
Width of Mixer 2485 mm
Drum Thickness 5 mm
Water tank Capacity 450
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25. 7.0 Merits & Demerits of Ready-Mix Concrete:-
Merits of Ready-Mix Concrete
• A centralized concrete batching plant can serve a wide area. Site Mix trucks can serve a
larger area including remote locations that standard trucks cannot.
• The plants are located in areas zoned for industrial use, and yet the delivery trucks can
service residential districts or inner cities. Site Mix trucks have the same capabilities.
• Better quality concrete is produced. Site Mix can produce higher compression strength
with less water than standard batching methods.
• Elimination of storage space for basic materials at site. Standard Batch plant need more
room for their operation than Site Mix trucks.
• Elimination of procurement / hiring of plant and machinery
• Wastage of basic materials is avoided. With a Site Mix truck, there is less waste and wash
out. This is better for the environment.
• Labor associated with production of concrete is eliminated. It takes more people to
operate a standard batch plant than a Mobile Mix truck.
• Time required is greatly reduced. One Mobile mix truck can produce 8 yards of concrete
in 8 minutes. It can also operate continuously without needing to be moved away from
the pump truck. One Mobile mix truck can produce 460 yards of concrete in an 8 hour
shift. Where standard trucks must stop and move off the pump to bring in the next truck.
So to deliver the same amount of concrete it will take nearly 3 more hours with a
standard truck. This will increase labor cost.
Demerits of Ready-Mix Concrete
• The materials are batched at a central plant, and the mixing begins at that plant, so the
travelling time from the plant to the site is critical over longer distances. Some sites are
just too far away, though this is usually a commercial rather than technical issue.
• Generation of additional road traffic; furthermore, access roads, and site access has to be
able to carry the weight of the truck and load. Concrete is approx. 2.5tonne per m³.
• This problem can be overcome by utilizing so-called 'minimix' companies, using smaller
4m³ capacity mixers able to access more restricted sites.
• Concrete's limited time span between mixing and going-off means that ready-mix should
be placed within 10 minutes of batching at the plant.
• Modern additives modify precisely that time span however, the amount of additive added
to the mix is very important.
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26. 8.0 Manufactures in India:-
1. APOLLO INFRATECH PVT. LTD. …………...Mehsana
Firm type Private LTD.
Level to expand National
Products/Services Concrete batching plant, Transit mixers
Production 20cum/hr., 30
cum/hr.,40cum/hr.,60cum/hr.,90cum/hr.
Depreciation 15 years(12,000 hours)
2. NILKANTH ENGINEERING WORKS.......... Ahmedabad
Firm type Proprietorship
Level to expand International
Products/Services Mobile concrete batching plant,
Ready mix concrete batching / mixing plant
Production 15cum/hr., 20 cum/hr., 30cum/hr., 50cum/hr.,
Depreciation 15 years(12,000 hours)
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27. 3. UNIVERSAL CONSTRUCTION MACHINARY & EQUIPMENT ....Pune
Firm type Private
Level to expand International
Products/Services Batching plant, Concrete mixer, earth
compacter,
Production 45cum/hr., 60 cum/hr., 80cum/hr., 120cum/hr.,
Depreciation 10 o 15 years
4. MACONS …………………Ahmedabad
Firm type Private
Level to expand National
Products/Services Batching plant, Concrete mixer, Transit mixer,
dumper, Concrete paver, Wet mixed
macadam,
Production 20cum/hr., 24 cum/hr., 30cum/hr., 36cum/hr.,
Depreciation 10 to 15 years
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