Beruflich Dokumente
Kultur Dokumente
CHAPTER I
ABSTRACT
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 as per specifications of the customer, at a centrally located batching Plant. It is
then 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 tuck, which keeps the mixed concrete in correct
form. This project deals with the advantages, disadvantages and the quality control in the
preparation of the concrete, of and the preparation procedure followed at the ready mix plant
In introduction we have seen that the basic information about the RMC & its
management. After that we consider the history of RMC in india Detail Study of RMC plant
& its procedure and find out problems releted to RMC plant Study the how to manage RMC
plant .We are studying about the Quality management, Material management, Human
resource management, Waste management etc. After the studying all this management and
personal visit to RMC plant we give the better solution on all problems on RMC plant .and
Make RMC plant economical , efficient & eco-friendly
In this project we find problems faced by RMC plant & give solution on that problem
also the study of disadvantages and give solution on that.
Page 1
CHAPTER II
AIM AND OBJECTIVES
2.1AIM Analys the problems of rmc plant management and to find the solution for that
problems
Page 2
CHAPTER III
RESERCH METHDOLOGY
PROJECT PARAMETERS: Capacity:The production capacity of a Ready-Mix Concrete Plant varies according to the
capacity of the Batching Plant used. Most commonly used RMC Plants will be having a
production capacity
Land:An extent of around dry land is required for setting up a Ready-Mix Concrete Plant.
Location:The project is proposed to be located at near to developing area
Raw Material & Utilities:The Raw materials that go into production of concrete are Cement, Aggregates (Sand
& Metal), Additives and Water. M20 grade concrete is the most widely used, where the
Cement/Sand/Metal/Water mix is in the ratio of 1 : 1.5 : 3.5 : 0.5. Since uninterrupted
availability of raw materials is the most fundamental success factor for any RMC Plant,
options for backward integration (quarry/ metal crushing unit/cement plant/clinker grinding
unit) should be carefully considered and analysed while choosing the Plant location.
Plant & Machinery:The main items of mechanical equipment involved in the ready-mix concrete
manufacture are the Concrete Batching Plant, Transit Mixer and Concrete Pump. M/s.
Schwing Stetter India (P) Ltd is the leading supplier of RMC equipments in the country..
Manpower:The total manpower requirement for a typical RMC Plant would be depends on
capacity of RMC plant
Cost of the Project:The total project cost of RMC is depend on rate of land, machines, equipment, &
capacity of project, availability of basic sources
Financial Arrangement :Financial arrangement done by taking loan from bank
Conclusion:Ready Mix Concrete is a modern technique of production of concrete in
large quantities away from the actual site of placing. It is very useful in cities
where demand of concrete is very high and construction sites are in
congested areas, where mixing on site is not possible. The Supervisory and
labour costs associated with production of RMC is less, and the quality of
concrete is high. It is suitable for huge industrial and residential projects
where time plays a vital role.
For further
Page 3
Management parameters :Ready mix concrete plant is situated near to the developing area. In large scale
construction project RMC should be situated on actual site location or near to the site
location. In that case small area to be used for example batching plant, material storage,
admixture storage, control room, RMC plant setup, etc.
RMC plant also situated in a developing area because of now a days we are using
RMC for a large scale or a small scale projects. RMC plant should be situated so that all the
needs of RMC will be fulfilled like a water resource, aggregate, cement, fly ash, crush sand,
etc are easily available to the RMC plant.
RMC plant should not be near to the residential areas, so as it should not affect
surrounding area.
Terminology that is used in Quality Plan: QUALITY CONTROL also called PROCESS CONTROL
As those quality assurance actions and considerations necessary to assess production
and construction process so as to control the level of quality being produced in the end
product. This concept of quality control includes sampling and testing to monitor the process
but usually does not include acceptance sampling and testing
QUALITY ASSURANCE (QA) :All those planned activities and systematic actions necessary to provide adequate
confidence that a product or service will satisfy given requirements for quality. Within an
organization, QA serves as a management tool. In contractual situations, QA serves to
provide confidence in the supplier
Goals for documenting plant QMSThe QMS consists of those processes, resources, policies, materials and activities that
influence your product and service quality. It is important that you define, document,
implement, maintain, and continuously improve your QMS. Documentation of your QMS
should not be the goal, but instead be a means of achieving your goal. Identify the purposes
for documenting your QMS which may include to:
Demonstrate to your customers your ability to consistently provide ready mixed
concrete that meets their performance criteria and/or applicable specifications;
Provide continuity and uniformity of processes;
Enhance training;
Improve customer satisfaction; and
Establish a measurement system to facilitate continuous improvement through
statistically based concepts, when applicable
MATERIAL MANAGEMENT :-
Page 4
MANPOWER:The total manpower requirement for a typical RMC Plant would be depends on
capacity of RMC plant
CHAPTER IV
LITERATURE REVIEW
PAPER I:IMPERIAL COLLEGE OF ENGINEERING AND RESEARCH
Page 5
Assistant Professor & Research Scholar, Civil Engineering Department, B.V.M. Engineering
College,
Vallabh Vidyanagar Gujarat India
In these paper auther invent new method Analytic Hierarchy Process (AHP). as a tool
to help with solving technical and managerial problems. Ready Mix Concrete (RMC)
industry is continuously growing all over the world.
Author says that The entry of foreign firms and major Indian cement producers in this
field are likely to provide the necessary boost to this industry in the future and speedy
construction grow up in India
Ready Mix Concrete (RMC) industry is continuously growing all over the world so in
these paper we study Analytic Hierarchy Process (AHP) and study of advantages of RMC
PAPER III
Debasis Sarkar, Assistant Professor, Constructionand Project Management, CEPT
University, Ahmedabad
In these paper author states that Quality Control of Ready Mixed Concrete can be
divided into three convenient areas like forward control, immediate control and retrospective
control.
Author find out solution for quality control , improve efficiency & improve
productivity he invent Statistical Quality Control (SOC) method and its give profit and
satisfaction to customer
Quality control by Statistical Quality Control (SOC) it improve efficiency & profit
and give satisfaction to customer.
CHAPTER V
THEORY ON RMC PLANT
INTRODUCTION:The Indian construction industry has been traditionally labour oriented. The pace of
mechanization in the past has been very slow due to the availability of cheap labour in
IMPERIAL COLLEGE OF ENGINEERING AND RESEARCH
Page 6
abundance, lack of capital investment and the highly fragmented nature of the construction
industry. The degree of mechanization is still around 25%-30% while it is well above 70% in
most of the developed countries.
The liberalization of Indian economy from 1991 onwards paved the way for largescale investments in infrastructure, industrial, housing and agriculture sectors. The new age
constructions required speed and superior quality to obtain profitable life cycle cost of the
projects. The emerging scenario helped to increase the pace of mechanization and facilitated
the establishment of RMC plants on commercial scale to synchronise with the over all
development strategy. RMC in India on commercial scale started in 1993 at Pune with only
one plant. It has achieved nearly 15% share of the total concrete produced in the country. In
some major cities, like Bangalore, Hyderabad, Mumbai and Chennai the share of RMC has
reached as high as 50% to 60%. The growth prospects of RMC in India are enormous,
provided requisite support is provided by the regulatory authorities, consumers and decision
makers during its formative years.
Concrete is the largest man made material in the world and stands second to water in
per capita consumption. It is estimated that world over about 3800 million tons of cement and
8000 million tons of concrete were used during the year 2013. Average per capita annual
consumption of cement worldwide is about 500 kg against 210 kg in India. Similarly world
over per capita concrete consumption is about 1 ton while it is 500 kg in India. Though
cement and concrete consumption is expected to grow at the average rate of 3% to 4% world
over, but in India 6% to 8% growth is likely to take place during the next decade. It is
therefore very important from life cycle cost, durability and environmental considerations
that majority of concrete is produced in centralized RMC plants.
One of the major causalities of heavy reliance on labour intensive techniques of
construction is the quality of work. Site-mixed concrete has serious limitations as far as
quality of concrete and speed of construction are concerned. Generally cost remains the
driving factor in deciding the award of construction contracts and very little or no premium is
placed on quality. As a result many structures have shown premature deterioration and the
cost of repairs and rehabilitation is proving prohibitive. Now growing realization is surfacing
that quality and consistency cannot be achieved by relying on age-old techniques of
construction.
The growth prospects of RMC in India in this context looks very bright but the RMC
has not maintained the desired pace of growth in spite of this realization due to numerous
constraints.
Page 7
ADMIXTURE:
FLY ASH
WATER
1.AGGREGATEAggregates are the important constituents in concrete. They give body to the concrete,
reduce shrinkage and effect economy. Earlier, aggregates were considered as chemically inert
materials but now it has been recognised that some of the aggregates are chemically active
and also that certain aggregates exhibit chemical bond at the interface of aggregate and paste.
The mere fact that the aggregates occupy 70-80 per cent of the volume of concrete, their
impact on various characteristics and properties of concrete is undoubtedly considerable. To
know more about the aggregates which constitute major volume in concrete.
Collect the aggregate sample from different locations at different depths from the site
immediately after unloading the aggregates from the trucks. Collect the samples at least from
10 to 15 locations.
Thoroughly remix the sample collected from various places & depths of the trucks or
from the stocks.
Page 8
The material so sampled only should be taken for testing. The Indian standards
recommend to sample the aggregates as above. However it recommends collecting samples
from different sub lots which are not practical as it takes long time to build up the lots at site.
Hence the method suggested above may be conveniently adopted at site.
2. CEMENT
Cement is a binder material which sets and hardens independently, and can bind other
materials together. Cement is made up of four main compounds tri-calcium silicate (3CaO
SiO2), di-calcium Silicate (2CaO SiO2), tri-calcium acuminate (3CaO Al2O3), and tetracalcium alumina ferrite (4caco Al2O3 Fe2O3).tetra-calcium alumina ferrite (4CaO Al2O3
Fe2O3). In an abbreviated notation differing from the normal atomic symbols, these
compounds are designated as C3S, C2S, C3A, and C4AF, where C stands for calcium oxide
(lime), S for silica and A for alumina, and F for iron oxide. Small amounts of un combined
lime and magnesia also are present, along with alkalis and minor amounts of other elements.
3. ADMIXTURE:
A substance added to the basic concrete mixture to alter one or more properties of the
concrete; i.e. fibrous materials for reinforcing, water repellent treatments, and
colouring compounds. 18
Air-entraining admixtures (mainly used in concrete exposed to freezing and thawing
cycles)
Water-reducing admixtures, plasticizers (reduce the dosage of water while
maintaining the workability)
Retarding admixtures (mainly used in hot weather to retard the reaction of hydration)
Accelerating admixtures (mainly used in cold weather to accelerate the reaction of
hydration)
Super plasticizer or high range water-reducer (significantly reduce the dosage of
water while maintaining the workability)
Miscellaneous admixtures such as corrosion inhibiting, shrinkage reducing,
colouring, pumping tc.
The role of admixture is ready mixed of concrete is same as that in normal concrete.
However, admixture used in RMC is modified to meet the requirement of pumpable concrete
and other properties of concrete. The types of admixture used in RMC are generally termed
as Super plasticizers.
The history of admixture is as old as history of concrete. There are several types of
admixture available in market. But few admixtures namely Plasticizers and Super plasticizers
are of recent interest. These of admixture were initially developed in Japan and German
around 1970. IN India use of admixture was recognized after 1985.In 1990 admixture started
to gain Importance after introducing Ready Mixed Concrete. The importance of admixture
was further recognized after revision on of IS: 456 - 1978. The earlier versions of IS 456 have
IMPERIAL COLLEGE OF ENGINEERING AND RESEARCH
Page 9
permitted to use w/c ratio as high as 0.65 in RCC works. The Revised IS 456-2000 has
Restricted the w/c ratio to 0.55 for mild exposure and 0.50 for moderate exposure ,0.45 for
severe and very severe exposure and 0.40 for extreme weathering conditions. The restriction
on w/c ratio has made the use of admixture all the more compulsory ingredient of concrete.
Increasing workability
Accelerate or retard the setting time of concrete.
Reduce segregation and bleeding in concrete.
Improve pump ability.
4. FLY ASH:Fly ash is a by-product from coal-fired electricity generating power plants. The coal
used in these power plants is mainly composed of combustible elements such as carbon,
hydrogen and oxygen (nitrogen and sulphur being minor elements), and non combustible
impurities (10 to 40%) usually present in the form of clay, shale, quartz, feldspar and
limestone. As the coal travels through the high-temperature zone in the furnace, the
combustible elements of the coal are burnt off, whereas the mineral impurities of the coal
fuse and chemically recombine to produce various crystalline phases of the molten ash. The
molten ash is entrained in the flue gas and cools rapidly, when leaving the combustion zone
(e.g. from 1500C to 200C in few seconds), into spherical, glassy particles. Most of these
particles fly out with the flue gas stream and are therefore called fly ash. The fly ash is then
collected in electrostatic precipitators or bag houses and the fineness of the fly ash can be
controlled by how and where the particles are collected. Fly ash use improves concrete
performance, making it stronger, more durable, and more resistant to chemical attack. Fly ash
use also creates significant benefits for our environment.
The size of fly ash ranges from 1.0 to 100 micron & the average size is around 20
microns. It is found that particle size below 10 microns contributes towards early
Development of strength (7& 28 days). The particle size of fly ash between l0 & 40 microns
Contributes towards the development of strength between 28 days & 1 year. The particle size
above 45 microns does not contribute towards development of strength even after 1 year and
for all practical purpose they should be considered only as sand.
The fly ash is generally used in the concrete in the following ways. : As partial replace for cement.
As partial replacement for sand.
As simultaneous replacement for both cement and sand
Page 10
5. WATER:The pH value of water should be in between 6.0 and 8.0 according to IS 456-2000.
The sea Water generally contains salinity of about 3.5% in which about 80% is
sodium chloride. Many researchers have been conducted to study the corrosion problem of
steel Embedded in concrete where sea water is used as mixing water in concrete nevertheless
the Indian standard is adamant & do not permit using sea water for mixing or curing in
reinforced Concrete constructions, but allows for using of sea water only for PCC work that
too under unavoidable circumstances.
Page 11
CHAPTER VI
EQUIPMENTS REQUIRED:6.1 BATCHING PLANT:The principal functional elements of every stationary concrete production Plant comprises of
the following:
Storage of materials - Silos, containers and bins
Batching arrangement
Measuring and recording equipment
Mixing equipment
Control systems
Electrical, hydraulic and pneumatic drives
Conveying systems (belt / screw conveyors)
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 litronic
MFM 85 moisture recorders. These recorders actually measure the moisture present in sand
while the entire batch flows past. A recording unit calculates the average moisture value of
the sand and passes on the information to the batching control unit to allow corrective action
to be taken. The system operates to an accuracy of as low as 0.2% relative moisture.
Consistency of the mix is generally checked by visual observation later confirming it
with a workability test like the slump test. However, in modern plants consistency of the
concrete mix is checked by a remote recording system which is automatic, easy and more
accurate
iii) Aggregates :The storage of aggregates is done in various way depending on the type of plant.
There are basically three types of plants generally in use. Vertical Production Plant
Page 12
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.
They can be again broadly classified into four types:Star pattern aggregate storage
Storage in tall silo
Storage in pocket silo
Inline aggregate storage silos
The star bin storage of aggregates is most popular in India mainly because of climate
conditions. The aggregates can be stored exposed to ambient temperature in different
compartments forming a star type pattern. A storage capacity of up to 1500 CuM is possible
in this type. The star pattern aggregates are stored in four to six compartments. They are
bulked at a 45 degree flow angle against the batching plant's bulkhead and partition wall of
the compartments using a boom type dragline loader. The drag-line operations are either fully
manual, semi automatic or fully automatic. Fully automatic dragline loader system operator.
Page 13
Power Mixer
Single Shaft
Twin Shaft
Pan type
Pan type with
additional
agitator
Capacity
CuM
(Compacte
d
concrete)
Output CuM/hr
(Compacted concrete)
Mixing Time (Sec)
Max.
Aggregate
size
(mm)
3
3.5
3
30
120
120-150
120
15
-
150
190
64
140
64
Page 14
Page 15
CHAPTER VII
MIXING PROCESS:Thorough mixing of the materials is essential for the production of uniform concrete.
The mixing should ensure that the mass becomes homogeneous, uniform in colour and
consistency. There are three methods adopted for mixing Ready Mix Concrete.
Page 16
Page 17
The tilting drum mixer:Tilting drum mixer is the most common American central mixing unit. Many centralmix drums can accommodate up to 12 yd3 and can mix in excess of 200 yd3 per hour. They
are fast and efficient, but can be maintenance-intensive since they include several moving
parts that are subjected to a heavy load.
Page 18
Horizontal shaft mixers have a stationary shell and rotating central shaft with blades
or paddles. They have either one or two mixing shafts that impart significantly higher
horsepower in mixing than the typical drum mixer. The intensity of the mixing action is
somewhat greater than that of the tilt drum mixer. This high energy is reported to produce
higher strength concrete via to thoroughly blending the ingredients and more uniformly
coating the aggregate particles with cement paste. Because of the horsepower required to mix
and the short mixing cycle required to complete mixing, many of these mixers are 4 or 5 yd3
units and two batches may be needed to load a standard truck or agitator.
Pan mixers:
Pan mixers are generally lower capacity mixers at about 4 to 5 yd3 and are used at precast
concrete plants.
Slurry Mixing
The slurry mixer is a relative newcomer to concrete mixing technology. It can be
added onto a dry-batch plant and works by mixing cement and water that is then loaded as
slurry into a truck mixer along with the aggregates. It is reported to benefit from high energy
mixing. Another advantage is that the slurry mixer reduces the amount of cement dust that
escapes into the air.
Page 19
CHAPTER VIII
Page 20
CHAPTER IX
NEED OF EFFECTIVE RMC PLANT MANAGEMENT
Concrete demand by customer in developing area.
Cost control on aggregate for size, shape and grading. Not exercised on a site
Blocking of roads/approaches.
Dust pollution.
Manual operation.
Wastage materials.
Quality assurance.
Restricted space.
Speed on construction site.
Economy management.
Page 21
CHAPTER X
CASE STUDY :PROJECT PARAMETERS
Capacity
The production capacity of a Ready-Mix Concrete Plant varies according to the
capacity of the Batching Plant used. Most commonly used RMC Plants will be having a
production capacity of 30 m3/hr (90,000 m3/year, based on 300 working days and single shift
of 10 hours).
Land
An extent of around 1 acre of dry land is required for setting up a Ready-Mix
Concrete Plant.
Location
The project is proposed to be located at Amanora town city corporation limited
( RMC plant )
Raw Material & Utilities
The Raw materials that go into production of concrete are Cement, Aggregates (Sand
& Metal), Additives and Water. M20 grade concrete is the most widely used, where the
Cement/Sand/Metal/Water mix is in the ratio of 1 : 1.5 : 3.5 : 0.5. Since uninterrupted
availability of raw materials is the most fundamental success factor for any RMC Plant,
options for backward integration (quarry/ metal crushing unit/cement plant/clinker grinding
unit) should be carefully considered and analyzed while choosing the Plant location.
Plant & Machinery
The main items of mechanical equipment involved in the ready-mix concrete
manufacture are the Concrete Batching Plant, Transit Mixer and Concrete Pump. M/s.
Schwing Stetter India (P) Ltd is the leading supplier of RMC equipments in the country.
The total cost of machinery for a 30m3/hr RMC Plant is around Rs.200 Lakhs.
Manpower
The total manpower requirement for a typical RMC Plant would be around 20
numbers.
Cost of the Project
The total project cost for setting up a 30m3/hr RMC Plant would be around Rs.400
Lakhs, including cost of 1 acre land. The project implementation period would be 12 months.
Ready Mix Concrete Plant KSIDC
Page 22
Means of Finance
Promoters contribution-100.00
Unsecured Loan -20.00
Term Loan Banks -100.00
Total Project Cost-220.00
Sales Turnover
The Revenue at optimum utilisation (80%) would be around Rs. 3888 Lakhs.
FINANCIAL INDICATORS
The Profit after Tax is Rs.123 Lacks.
The Break Even Point (BEP) for the project is 58%.
The Debt Equity Ratio (DER) for the project is 1:1
Average Debt Service Coverage Ratio (DSCR) is 3.78
The average Internal Rate of Return (IRR) for the project is 28.68%.
CONCLUSION
Ready Mix Concrete is a modern technique of production of concrete in large
quantities away from the actual site of placing. It is very useful in cities where demand of
concrete is very high and construction sites are in congested areas, where mixing on site is
not possible. The Supervisory and labour costs associated with production of RMC is less,
and the quality of concrete is high. It is suitable for huge industrial and residential projects
where time plays a vital role.
Page 23
Page 24
Page 25
Page 26
REFERENCES :- :1 .Ready-Mixed Concrete growth prospects in India- A K Jain*, Grasim Industries Ltd, India
http://cipremier.com/100027032
IMPERIAL COLLEGE OF ENGINEERING AND RESEARCH
Page 27
2. An Approach for Ready Mixed Concrete Selection for Construction Companies through
Analytic Hierarchy Process- Ashish H. Makwana 1, Prof. Jayeshkumar Pitroda
International Journal of Engineering Trends and Technology (IJETT) - Volume4 Issue7- July
2013
3. Minimizing Material Inventory in Ready Mixed Concrete PlantsIJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 1 Issue
8, October 2014.
www.ijiset.com
4. Quality Management System for Ready Mixed IS 456 2003
5. Construction management S.Seetharaman
6. Concrete Technology Theory and Practice, M.S SHETTY, S.Chand- New Delhi.
7 .RMC in India (June 2001), Civil Engineering & Construction Review
8. IS 4926-2003, Standard on Ready mixed concrete Code of Practice, BIS, New Delhi.
9. IS 383, Indian Standard specification for coarse and fine aggregates from natural sources
for concrete ( Second Revision )
10 .IS 10262-2009, Indian Standard Concrete Mix Proportioning- guidelines (First Revision)
WEBSITES :1. http://cipremier.com/100027032
2. www.ijiset.com
3. http://www.rdcconcrete.com/
4. http://www.wikipedia.org/
Page 28
Page 29
Page 30
Page 31
Page 32
Page 33
Page 34
Page 35
Page 36
Page 37
Page 38
Page 39
Page 40
Page 41
Page 42
Page 43