READY MIX CONCRETE: AN OVERVIEW

BY BHUPENDRA SINGH RAGHAVA M TECH - CONSTRUCTION MANAGEMENT SEM- I

READY MIX CONCRETE

RMC is a specialized material in which the cement

aggregates and other ingredients are weigh-batched at a plant in a central mixer or truck mixer, before delivery to the construction site in a condition ready for placing by the builder. Thus, `fresh' concrete is manufactured in a plant away from the construction site and transported within the requisite journey time. The RMC supplier provides two services, firstly one of processing the materials for making fresh concrete and secondly, of transporting a product within a short time.

HISTORY OF RMC
First introduce by Architect Jurgen Heinrich Magens, he

get his patented of RMC in Germany in 1903. 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 first concept of transit mixer was also born in 1926 in the United States. In 1939, the first RMC plant was installed in United Kingdom and in 1933 first specifications on RMC was published in United Kingdom.

Figure: Transit mixer in late 1940s and Concrete pump in late 1940s (Ambuja Cement Literature Vol. 90)

 In India RMC was first initially was used in 1950 during

the construction sites of Dams like like Bhakra Nangal, Koyna. RMC was first fully established in Pune in the year 1991 by private companies which was close later. RMC was successfully established sometime after 1994 in India. As per the available record upto 2003, there are around 76 RMC plant in 17 cities with a total capacity of around 3875 CuM/hr, producing 3.8 million CuM of concrete per year.

ADVANTAGES OF RMC
SUPERIOR QUALITY REDUCED THE WASTAGES OF MATERIAL ELIMINATE THE PROBLEM OF STORAGE OF

MATERIAL REDUCE SUPERVISION & LABOUR COST SAFE & HYGENIC CONDITION FLUCTUATION OF RAW MATERIAL COST & NONAVABILITY OF MATERIAL ELIMINATE REDUCES THE PROBLEM OF INSPECTION, CHECKING & TESTING ROADS & FOOTHPATH ARE NOT BLOCKED IMPROVE THE ENVIRONMENT

SCOPE OF RMC IN INDIA

The World Bank's India Cement industry Restructuring Project"

under which a technical study report on the development of market for bulk cement in India was made in 1996, proved to be positive development towards modernization of cement distribution system in India, including setting up Ready mix concrete Plants. The objective of this technical study was to formulate an action plan for the development of market for bulk cement in large cement centres in India and for gradual shift. from the traditional mode of transportation in bags to bulk transportation through setting up of ready mixed concrete plants in different parts of the country. The recommendation of the action plan provided a useful guidance towards expanding bulk cement market thus paving a way for installation or ready mixed concrete plants in India

 According to Cement Manufacturers Association, RMC is being

increasingly recommended for all major public construction work such as highways, flyovers. In India it can grow to consume 40-45 percent of cement by 2015 through setting up of RMC plants in various consumption centers. According to European Ready Mixed Concrete Organization (ERMCO) .The marketing of RMC should no more be in terms of strength grades only, but a combination of strength durability classification as per the Concrete Codes which improves the sellability of RMC in terms of the requirements of the projects. Appropriate environmental, safety and health regulations for the working force need to be kept in mind in the management and operation of RMC.

Figure : RMC Market Potential (CE&CR, June 2001, pg.no.30)

TYPES OF BATCHING PLANTS

1) Centrally Mixed Concrete or Wet batch mixer In Centrally mixed concrete, the mixing is done at a central plant & the mixed concrete is then transported usually in the truck agitator truck which revolves slowly so as to prevent segregation and undue stiffening of the mix. 2) Truck mixed concerte or Dry batch concrete plant In the truck mixed concrete, the materials is batched at a central plant but are mixed in a mixer truck either in transit to the site or immediately prior to the concrete is being discharged. Transitmixing permits a longer haul and is less vulnerable in case of delay, but the capacity of a truck used as a mixer is only 63 per cent, or even less, of the drum while for central-mixed concrete is 80 percent.

BATCHING AND MIXING PLANTS

a) Storage of Materials i) Cement

Cement is generally stored in silos. The loading of cement is done with the help of pneumatic blower systems
Figure: Pneumatic blower system on a cement bulker unloading cement into silos.
(Ambuja Cement Literature Vol. 12)

ii) Water

Water is generally stored in tanks located close to the plant. It is accurately measured by a water gauge and microprocessor controlled system. The modern plants have new electronic MFM 85 moisture recorders .
Figure: Electromechanical weighing system used on modern batching plant for cement and aggregates (Amubuja Cement Literature Vol.no.12)

iii) Aggregates
Vertical Production Plant In this the aggregates are stored above the batching and mixing elements, in one or more silos. These plants are not suitable for relocation at short intervals of time. As the aggregates are stored in silos it is relatively easy to protect the aggregates from very low temperature in winter period.

Figure: Schematic view of the Vertical Batching Mixing Plant with vertical aggregate and cement storage silos. ( Ambuja Cement Literature Vol.12)

 Horizontal Production Plant

They can be again broadly classified into four types i) Star pattern aggregate storage ii) Storage in tall silo iii) Storage in pocket silo iv) Inline aggregate storage silos The star bin storage of aggregates is most popular in India mainly because of climate conditions. A storage capacity of upto 1500 CuM is possible

Figure: Horizontal Batching Mixing Plant with vertical aggregates & cement silos (Amubuja Cement Literature Vol.no.12)

Figure: Rear view of the batching mixing plant with star pattern having four aggregate storage bins (Amubuja Cement Literature Vol.no.12)

b) MIXING ARRANGEMENTS There are various types of concrete mixers used on the concrete production plant. The two basic types are free fall mixers and power mixers Free fall mixer consists of a rotating drum with blade fixed on the drum's interior. As the drum rotates, the material inside is lifted and dropped. Most of the imported plants have power mixer. The power mixer sets in motion the materials positively. The materials get thoroughly mixed by rotating arms.

Figure: Cross sectional view of the single shaft compulsory power mixer. (Amubuja Cement Literature Vol.no.12)

Figure: Twin shaft compulsory power mixer (Amubuja Cement Literature Vol.no.12)

c) CONTROL SYSTEMS

Figure: a) Fully automatic control panel of a modern mixing plant. b) Microprocess Control System on the modern mixing plant. (Amubuja Cement Literature Vol.no.12)

d) TRANSPORTATION EQUIPMENT: - TRANSIT MIXER

Normal capacity Hydrulic Drive of Mixer Water tank capacity Mixer trucks 4 to 12 CuM Separate engine or driven by truck engine 192 to 2000 litres Twin axles for 4 CuM capacity Three axles for 6 to 7 CuM capacity, three/four axles for 8 to 10 CuM capacity, Semi trailer truck for 10 to 12 CuM.

SAMPLING OF CONCRETE
As per IS 4926-2003 After the truck-mixer has re-mixed

its delivery on site allow at least the first one-third of a m3 of concrete to be discharged prior to taking any samples. Take at least 4 incremental samples from the remainder of the load avoiding sampling the last cubic metre of concrete. As per BS 1881: Part 101 & Part 102, describe the recommended sampling methods for ready mixed concrete in British code. Using a standard scoop, this can collect about 5kg of normal weight concrete.

SAMPLING OF CONCRETE
BS 1881: Part 102 (The Alternative Method)

An initial discharge of at least 0.3 m3 is made before a sample of six scoopfuls is collected from the moving stream; The sample is then re-mixed on a non-absorbent surface and split into two equal parts. Each part is then tested or slump, with the average of the two tests recorded as the test result.
The Alternative method of collecting sample (CE&CR, June 2001, pg. no. 35)

TESTING OF CONCRETE
COMPRESSIVE TEST

As per IS 456 -2000, a result is the average of the compressive test specimens made for the same sample of concrete. Individual variation should not be more than 15 Percent of the average. SLUMP TEST According to ASTM C94-94, the time during which the cement and moist aggregate are allowed to remain in contact is limited to 90 minutes; BS 5328: part 3: 1990 allows 2 hours.

The 90 minutes limit can be relaxed by the purchaser. With the use of retarding admixtures, the time limit can be extended to 3 or even 4 hours. The United States Bureau of Reclamation provides for an extension of 3 to 6 hours in the time of contact between cement and wet aggregate in transport prior to mixing. In IS 4926-2003, The general requirement is that concrete shall be discharged from the truck-mixer within 2 h of the time of loading. However, a longer period may be permitted if retarding admixtures are used or in cool humid weather or when chilled concrete is produced.

NEED TO BE SPECIFIED FOR RMC

Characteristic strength or grade (N/mm2) Target workability or slump in mm required at site Maximum water to cement ratio Minimum cement content Maximum aggregate size Type of cement Mineral admixture and its proportion (Kg/m3) Maximum aggregate size Rate of gain of strength (for formwork removal or prestressing etc.) Maximum temperature of concrete at the time of placing (in extreme climatic conditions or in case of massive concrete pours) Type of surface finish desired. Method of placing Rate of supply desired to match the placing and compaction speed planned at site. Quantity of concrete required. Lift and lead of concrete transportation and placement at site. Frequency of concrete testing Details of materials and their required tests. Permeability tests required (if any) Placing of concrete in formwork to be under scope of RMC supplier (if required) Mode of measurement.

INFORMATION TO BE SUPPLIED BY THE PRODUCER

Name or number of the ready-mixed concrete depot. Serial number of the ticket. Date. Truck number. Name of the Purchaser. Name and location of site. Grade or mix description of the concrete. Specified target workability. Minimum cement content (if specified). Type of cement and grade (if specified). Maximum free water-cement ratio (if specified). Nominal maximum size of aggregate.

Generic type or name of any chemical and Quantity of concrete in m. Time of loading. Signature of the plant operator. A statement warning the purchaser of the precautions needed to be taken when working with cement and wet concrete.mineral admixtures included.

CHECKS BY CONSUMER BEFORE ORDERING THE RMC

Reliability of the plant and transit mixers Calibrations of all measuring devices and their accuracy. Mode of operation of plant should preferably be fully

automatic and not manual. Quality of materials proposed to be used. Adequacy of quantity of materials proposed to be used. Compliance of concrete specifications based on the mix parameters specified. Adequacy of testing facilities Time likely to be taken by transit mixers from plant to site and back.

CHECKS NEEDED AT SITE PRIOR TO RECEIPT OF RMC

Reinforcement layout
Adequacy of formwork Openings and chutes provided Adequacy of manpower and equipment Proper approach for transit mixers Proper platform to receive concrete. If pumping is proposed, the location of the pump

should be approachable from both sides

CHECKS NEEDED AT SITE DURING CONCRETING

Proper co-ordination between the RMC supply and placing and

compacting gangs. Proper signaling or communication at site is necessary. Workability of concrete within accepted limits. Adequacy of cohesiveness of concrete for pumpability. Water addition or chemical admixtures are not added during transportation . Temperature of concrete at the time of receipt at site (if specified). Continuous and steady supply at site and speedy unloading Retempering should not be allowed.

UNNECESSARY RESTRICTIONS ON SUPPLIERS OF RMC BY PURCHASER

Insistence on use of cement and admixtures of specific brands
Inappropriately low water to cement ratio Restriction on use of water reducing admixtures Insisting on Indian Standard method of concrete mix design Frequency of testing Fixed slump insisted upon Ambiguous specifications

Concrete Field strength should not be less than Target strength

THE CONSTRAINTS FACED BY RMC PRODUCERS AT PRESENT

High Cost Delayed payments and long credit by consumers RMC plants in cities are not permitted to be installed in

residential zones. High cost of the plant and equipment results in high capital costs. Bad quality of roads and traffic congestion and intermittent signals often delay the deliveries in metros. Availability of trained and skilled manpower for operations and maintenance of plant and equipment. Delays in placing, compacting and finishing at consumer's end causes delays in unloading of transit mixer and stiffening of the concrete mix. Quality of formwork and its adequacy

PROMOTING RMC IN INDIA

Ban any storage of materials at any construction site.
No public space shall be occupied by building materials during

construction. Government should come out and insist on RMC and quality. Transit mixers movements should be allowed through out 24 hrs. Government should given some taxes & import duties benefit. The government and local bodies can encourages the use of ready mixed concrete

CONCLUSION
DURABLE CONSIDERATION
OVERALL ECONOMY REALISATION OF THE ADVANTAGES BY

ENGINEERS AND CONSTRUCTION INDUSTRY

WIDELY ADOPTED THROUGH OUT THE WORLD

REFRENCES
Kaushal Kishore (June 2001), RMC: Some Technical Aspects,

Civil Engineering & Construction Review. Sanjay Bahadur (June 2001), RMC- A Non-Negotiable Approach to Durable Urban Infrastructure, Civil Engineering & Construction Review. Kshemendra Nath (June 2001), RMC- The Need for Partnership, Civil Engineering & Construction Review. Danish Rashid (June 2001), RMC: The Indian Answer to World Class Construction, Civil Engineering & Construction Review. IS 4926-2003, Standard on Ready mixed concrete Code of Practice, BIS, New Delhi. RMC on the move (Oct. 2003), Ambuja Technical Literature, Vol. No. 90 Mechanisations of concreting, Part I- Batching, Mixing & Transporting (Dec. 1996), Ambuja Technical Literature, Vol. No. 12

THANK YOU