Ready mixed concrete

1. INTRODUCTION

Concrete is one of the major components of a structure, particularly a multistoried

structure, where in it accounts for 30% - 50% of the total cost. The quality of concrete
has also a very direct bearing a on the strength & durability of the structure as a whole. It
is in this context that RMC assumes relevance.
Few things are more aggravating to produce on a worksite than concrete. Bags of
cement, sand, aggregate (gravel) & 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 & heavy ingredients have been loaded into the
Hooper, one small error in the wet/dry ratio can render an entire batch of concrete
unusable. One common solution to this messy & time consuming problem is “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.

This enables the places of manufacture and use of concrete being separated and
linked by suitable transport operation. This technique is useful in congested sites or at
diverse work places and saves the consumer from the botheration of procurement, storage
and handling of concrete materials. Ready mix concrete is produced under factory
conditions and permits a close control of all operations of manufacture and transportation
of fresh concrete. Due to its durability, low cost and its ability to be customized for
different applications, ready mix concrete is one of the most versatile and popular
building materials.

RMC is usually ordered in units of cubic yards or meters. 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 to 80
meters. It must remain in motion until it is ready to be poured, or the cement may begin
to solidify. The RMC concrete is generally released from the hopper in a relatively steady
stream through a tough system. Workers use shovels and hoes to push the concrete into
place.

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2. 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, an 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. By 1997, in Europe there were 5850 companies
producing a total of 305 million cusecs of RMC.
In USA by 1990, around 72% (more than 2/3 rd) of cement produced was being used
by various RMC plants. In Japan the first RMC plant was set up in 1949. By 1992, Japan
was the then largest producer of RMC, producing about 18,196 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.
The leading RMC supplier worldwide is the Mexican Concrete & cement company
CEMEX, & their main competitor is France-based Lafarge.
In INDIA, RMC plant arrived in 1950’s and the use of RMC was restricted to only
major construction projects such as, Bhakra Dam. Later on RMC was used for other large
projects such as construction of long span bridges, industrial complexes etc. The RMC
plant was set up in Pune in 1993.
The concept of RMC is still catching up in the country, cement majors are keenly
focusing on entering the new area in a big way. Cement majors, including Associated
Cement Companies, Grasim, L&T, India cements, Priyadarshini cements, Chettinad
cement & Madras cements, are foraying into the RMC business & the share of RMC is
expected to go up from present levels of around5% of the total cement production to the
global average of 70%. The teething troubles has been overcome by the RMC Industry &
at present there are over 37 RMC plants delivering over 1 lakh cubic meters of mixed
concrete every month. RMC plants are working in Delhi area also.

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

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3. METHODS OF PRODUCTION:
There are 2 general methods of producing RMC:
 Transit or Truck mixing
 Central Mixing
 Shrink Mixing

3.1 Transit Mixing:

In Transit Mixing, the dry materials are proportioned at the RMC plant, the water
being added & the mixing done en route to the job in a truck mixer, which essentially
consists of a mixer drum mounted on a conventional chassis. Power for rotating the drum
is obtained either from the truck engine or from an independent petrol engine. The truck
mixer is provided with a water supply tank with equipment for measuring the quality of
water entering the drum, & a revolution counter indicating the extent of mixing.
As soon as the mixer drum is charged with its complete batch of materials from the
batching plant, the truck proceeds to the concrete pouring point, the mixing operation
taking place en route, the water level and the mixing controls being operated by the
driver; where the length of the haul is long, delivery of freshly mixed concrete is assured
by starting the mixing operation towards the end of the haul. On arrival at the worksite,
the concrete is discharged over detachable chutes into receptacles or directly on to the
forms.

3.2 Central Mixing:

In central mixing, both the operations of proportioning & mixing are carried out at a
batching plant & deliver the mixed concrete to the site in an agitator truck, which keeps
the mix concrete in correct form.
In case of centrally mixed type, the drum carrying the concrete revolves slowly so
as to prevent the mixed concrete from “segregation” & prevent its stiffening due to initial
set.

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Central mixing is resorted to when there is likely to be a considerable period lag

between the time of mixing and the time of placing. With agitation a maximum of one
and half hours between mixing & placing can be allowed.
Another important consideration in favour of central mixing method is the fact that
more concrete can be transported in a single trip when the truck-mixer is used as an
agitator. The effect of this is to reduce the transportation charges, all other factors being
equal.

3.3 Shrink Mix:

Concrete that is partially mixed in a plant mixer and then discharged into the drum
of the truck mixer for completion of the mixing is called shrink mixed concrete. Central
mixing plants that include a stationary, plant-mounted mixer are often actually used to
shrink mix, or partially mix the concrete. The amount of mixing that is needed in the
truck mixer varies in these applications and should be determined via mixer uniformity
tests. Generally, about thirty turns in the truck drum, or about two minutes at mixing
speed, is sufficient to completely mix shrink-mixed concrete.

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PLACING OF CONCRETE:

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4. MATERIALS REQUIRED FOR RMC:

Admixtures: A substance added to the basic concrete to alter one or more properties of
the concrete, i.e. fibrous materials for reinforcing, water repellent treatment and colouring
compounds.

 Air-entrainment admixtures (mainly used in concrete exposed to freezing and

thawing cycles)
 Water reducing admixtures ,plasticisers ( reduce the dosage of water while
maintaining the workability)
 Retarding the admixtures(mainly used in hot weather to retard the reaction of
hydration)
 Super plasticiser or high range water reducer(significantly reduce the dosage
of water while maintaining the workability)
 Miscellaneous admixtures such as corrosion inhabiting, shrinkage reducing,
coloring.pumping etc.

Aggregate: Inert particles (i.e. gravel, sand, and stone) added to cement and water to
form concrete.

Cement: Dry powder that reacts chemically with water to bind the particles of
aggregate, forming concrete. Portland cement is typically used in concrete production.

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Fly Ash: Fly ash is a by product of coal fired electricity generating power plants. Mainly
composed of combustible elements such as carbon, hydrogen and oxygen (nitrogen and
sulfur 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 1500°C to
200°C 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.

5. READY MIX CONCRETE PLANT:

A ready mix concrete plant is a permanent installation with mechanical handling for
the storage, proportioning & mixing of materials. The location, size of the plant & layout
are governed by a number of considerations, depending upon local conditions which
require careful study before the design and construction of the plant are undertaken.

5.1 LOCATION:

In the operation of a RMC concern, the transportation of the concrete to the site of the
job is generally one of the most expensive items & the RMC plant should, as far as
possible, be situated in the centre of the market. This may be difficult proposition in a
very large cities where works requiring. RMC may be situated beyond the economical
radius for operations. In such cases; it may prove more economical to operate two or
more small plants, spread out to reduce the length of the haul, than to concentrate
production in a single large plant.

Another important consideration in the selection of a site is the facility of delivery

of materials to the plant. Location near the rail-head, from which a siding can be
constructed to the plant, would be more advantages in unloading the materials direct from
the wagons to their respective stockpiles.

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5.2 SIZE OF PLANT:

The size of plant will depend chiefly on the potential demand for which the plant
has to cater. This in turn is dependent upon the quality of concrete construction carried
out in a town or city.

Towns & cities undergoing a critical housing storage or those which are in the
process of industrial expansion would naturally provide a fruitful field for RMC
operation.

However, with increasing confidence amongst architects, engineers, contractors &

the public in a product of guaranteed quality & offered at rates which are competitive
enough to induce the adoption of RMC in preference to site-mixed concrete, the demand
will soar. The size should, therefore, be selected taking into account potential future
increase in production.

5.3 LAYOUT:

The plant layout should be so arranged that it satisfies that it satisfies the following
considerations: firstly, it ensures the maximum efficiency in operation; secondly, it
provides adequate space for the storage of materials & thirdly, it does not hamper future
expansion.

For faster operation & in order to reduce the traffic hazard within the plant, a one
way traffic should be adopted with vehicles entering & leaving from separate gateways &
the equipment being so arranged that the truck-mixers collect first the dry materials from
the weigh-batchers, then the water, and make a direct exit into the street. In order to
further reduce the amount of driving all the weighing equipment should preferably be
located near the front of the site or to close to the street exit, leaving the rear for the
receipt and the storage of materials.

The unloading & stockpiling of aggregates should be as close as possible to the

overhead compartment bins so that a minimum length of conveyer belts is required.
Besides reducing the initial investment it will afford faster operation & a reduction in
production cost.

Adequate space for the stockpiling of materials is very necessary to meet with the
irregular supply of cement & aggregates. This calls for the provision of sufficient space

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to accommodate the storage of materials to provide for a reserve stock of cement &
aggregates equivalent to 7-10 days normal consumption.

6. STATIC EQUIPMENT:
The static equipment required for RMC plant can be divided into the following
categories:

 Equipment for unloading aggregates & cement, stockpiling them in their

respective storage areas & elevating them into the overhead compartment bins.

 Overhead compartment bins for storing cement & various sizes of sand, Coarse
aggregates with weigh-batchers for accurate proportioning & discharge chutes.

 Water storage tank.

 Stationary mixers for central mixing plants.

 Office building & testing laboratory.

6.1 UNLOADING, STOCKPILING AND ELEVATING MATERIALS:

Aggregates may be delivered to the plant in railway wagons, Lorries or in

barges if the plant is sited near a water-front. Arrangements for unloading the materials
may be either mechanical or manual, but mechanical handling is invariably adopted for
elevating into the storage bins.

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In case of a fully mechanized system, a crawler crane, derrick or belt conveyors

are used for various operations. A crawler crane or derrick with a clamshell bucket will
unload the aggregates, stockpile them on the ground and place the aggregates into the
overhead compartment bins. In order to perform these operations efficiently the crane or
derrick should have a boom length which can conveniently reach above the tops of
overhead storage bins and the entire layout should be so arranged that only the minimum
change in the boom angle is necessary for any of the operations.

Another arrangement is to install a belt conveyer in a tunnel beneath the

aggregate stockpile with shaker in the roof of the tunnel to control the discharge of
various aggregates on to the conveyer. The conveyer in turn feeds an elevator, which
empties the aggregates at the top of the bin into the appropriate compartment.

The initial investment required for small-sized plant can be effectively cut down
by using a portable belt-conveyer for unloading the aggregates from the wagons and the
stockpiling them on the ground. Transportation of the materials to the bottom of the
storage bins is then done by means of Dobin- type dumpers fitted with pneumatic tyres
and having a capacity of about 1.5cu.yd, from which the materials are tipped into a pit at
the foot of the bin and conveyed up into the compartment by means of an elevator.

When the aggregates are delivered to the plant in Lorries, they are easily unloaded
directly to the stockpile and any of the methods described above can be used for
conveying and elevating into the storage bins.

Cement will generally be delivered to the plant either in bulk or in bags and its
storage under moisture-proof conditions is very essential. Cement can be unloaded from
wagons either by hand-operated scoops or power shovels onto a hopper adjacent to
wagon door, which feeds by means of a screw conveyer a closed-typed bucket elevator
the silo or storage bin in which the cement is kept. Cement can also be unloaded and
stored by a portable pump which forces the cement into the storage bin through a pipe-
line.

6.2 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 materials
easily. The aggregates required are fed by the means of aggregate belt conveyer. On the
aggregate belt conveyer the aggregate are weighed automatically by means of computer
from computer room present on the plant.

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INLINE BINS

6.3 SILOS:

Cement & Fly ash are stored in an airtight container called as “Silos”; the required
quantity of cement & Fly ash is extracted by the silos. There are two Cement silos & one
silo of Fly ash. The capacity of cement silo is 2 x 130 tons = 260 tons.

Cement & Fly ash are to feed holding hopper with the help of a screw conveyer. A
heavy duty cement screw conveyer is fixed in inclined position to convey the cement
from Manual Feeding Hopper to Cement Hopper. A suitable drive unit is also provided to
drive the screw.

The screw conveyer body and the screw are manufactured from heavy duty ‘C’
class pipe and the flutes are fabricated from 5mm plate. Running clearances provided
between body and flutes for smooth running. The screw is supported on both ends by
bearing and at center by hanger bearing having renewable hard bush. These bearing can
be adjusted with setting nuts so as to have proper alignment.

The screw conveyer is provided with suitable vertical supports. One inlet
connection is provided at the bottom end where manual-feeding hopper is connected &
one discharge connection at the top from where the cement is discharged to cement
weighing hopper. Flexible joint is provided between discharge connection & cement
weighing hopper. Two cleaning pockets, one in the middle and another at the bottom side
are also provided for emergency removal of cement from conveyer.

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Weigh-batchers are of many different types. They may be manually or automatically

operated and fitted either with bean scales and tell-tale dial or a spring less full reading
dial.

SILOS

6.4 WATER STORAGE:

A RMC plant generally makes provision for adequate storage of water to meet its
requirements for 2 to 3 days. Control over quantity of mixing water is an essential
requirement in concrete making for it bears a direct relation to the strength and quality of
the finished product. Equipment for the accurate measurement of water is, therefore, a
necessary item in any ready mix concrete plant.
The device adopted for the measurement of water will depend upon the method of
mixing and type of mixers. In a central mixing plant, this is introduced into the mixer
slightly ahead of the materials and the apparatus is of necessarily installed near the mixer
and at the plant site. Measurement of correct quantity of water at the plant site can be
transit mixing also when correct amount of water required for a batch of concrete
introduced into a compartment of mixer, and fed into the drum by truck driver during
transit.
However, modern truck mixers are equipped with calibrated water gauges and
controls for the introduction of water into drum and responsibility of ensuring the correct
measurement of water then devolves on driver.

6.5 STATIONARY MIXER:

The stationary mixer used in central mixing plant is of two types:

 Rotary mixer
 Tilting mixer

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In Rotary Mixer, the drum is cylindrical and revolves about a

horizontal axis. The drum has an opening at each end for charging and
discharging.

Tilting mixer type is equipped with a conical or bowl shaped drum

which revolves on an inclined axis, the concrete being discharged by tilting of
drum.

6.6 OFFICE BUILDING & TESTING LABORATORY:

The provision of an office building to house the staff required for the receipt of
orders and the day to day administration of plant requires no elaborate set up and is made
to suit the requirements of a plant. A small testing laboratory, equipped with apparatus
for the scientific design of concrete mixers testing of samples to check that specified
strength and quality are being achieved is, however, a necessary adjust to a Ready-Mixed
concrete plant.

7. TYPES OF PRODUCTION PLANTS

 Vertical Production Plant
 Horizontal Production Plant

7.1 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.

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

7.2 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. 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

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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
drag-line loader system operator.
The star bin type plant requires more space and as the aggregates are stored in open
they heat up at high ambient temperatures and freeze at very low temperatures. These
types of plants are not suitable in extreme weather conditions.
In silo type storage additional investment for loading equipment such as hopper,
bucket elevator or conveyor belt plus rotary distribution are required. They have large
active storage (upto 500 CuM) in a small areas. Loading is fully automatic, aggregates
are well protected in extreme climatic conditions and storage is very clean.

Figure: Schematic view of the Horizontal Batching mixing plant with the star pattern
aggregate storage bins at the rear & vertical storage silos. (Amubuja Cement Literature
Vol.no.12)
8. DELIVERY OF RMC
While ready mixed concrete can be delivered to the point of placement in a variety of
ways, the overwhelming majority of it is brought to the construction site in truck-
mounted, rotating drum mixers. Truck mixers have a revolving drum with the axis
inclined to the horizontal. Inside the shell of the mixer drum are pair of blades or fins that
wrap in a helical (spiral) configuration from the head to the opening of the drum. This
configuration enables the concrete to mix when the drum spins in one direction and
causes it to discharge when the direction is reversed.

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To load, or charge, raw materials from a transit mix plant or centrally mixed concrete
into the truck, the drum must be turned very fast in the charging direction. After the
concrete is loaded and mixed, it is normally hauled to the job site with the drum turning
at a speed of less than 2 rpm.

Since its inception in the mid-1920, the traditional truck-mixer has discharged
concrete at the rear of the truck. Front discharge units, however, are rapidly becoming
more popular with contractors. The driver of the front discharge truck can drive directly
onto the site and can mechanically control the positioning of the discharge chute without
the help of contractor personnel. Currently, because of weight laws, the typical truck
mixer is a 9 to 11 yd3 unit. The drums are designed with a rated maximum capacity of
63% of the gross drum volume as a mixer and 80% of the drum volume as an agitator.
Generally, ready mixed concrete producers, load their trucks with a quantity at or near the
rated mixer capacity. Fresh concrete is a perishable product that may undergo slump loss

depending on temperature, time to the delivery point on the job site, and other factors.

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Water should not to be added to the mix unless the slump is less than that which is
specified. If water is added, it should be added all at once and the drum of the truck mixer
should be turned minimum of 30 revolutions, or about two minutes, at mixing speed.

The ASTM C 94, Specification for Ready Mixed Concrete, indicates that the concrete
shall be discharged on the job site within 90 minutes and before 300 revolutions after
water was added to the cement. The purchaser may waive this requirement, when
conditions permit.

In certain situations, air-entraining, water reducing, set-retarding or high-range water

reducing admixtures may need to be added to concrete prior to discharge to compensate
for loss of air, high temperatures or long delivery times. The ready mixed concrete
producer will assist the purchaser in such circumstances.

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AN OVERVIEW OF RMC PLANT

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9. READY MIX CONCRETE COMPARED TO SITE MIX CONCRETE

READYMIXEDCONCRET
PARTICULARS SITE-MIXEDCONCRETE
E
PRODUCTION
Raw Material Near Mixer at site At Batching plant
Weighing Manual Computerised
Moisture Control Approximate Lab Control
W/C ratio Manual(approx.) Computerised
Dosing of admixture Manual(approx.) Computerised
Mixing Tilting mixer Non tilting single shaft mixer
Discharge Platform Transit mixer/pump
Rate 3 Cu.m/hr 30 Cu.m/hr

QUALITY
Degree of Control fair excellent
Yield variable consistent
Testing of fresh concrete once in 25 batches every batch

RAW MATERIALS
Selection/Sourcing Client/consultant skilled RMC personnel
Testing Client/consultant skilled RMC personnel
storage multi locational single point
storage space large limited and compact
requirement

DELIVERY Manual Transit Mixer

PLACING
Mode Manual/Hoist/Crane Concrete pump
Rate 1.5 Cu.m./hr 30 Cu.m./hr.
10. ADVANTAGES & DISADVANTAGESOF USING

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READY

MIX CONCRETE:
ADVANTAGES :

RMC is more advantageous to the consumer from both the technical and
economical aspects of concrete-making.

 Assures consistent quality through accurate computerized control of aggregates

and water as per mix designs.

 It facilitates speedy construction through programmed delivery at site and

mechanized operation with consequent economy.

 Elimination of material storage on congested building site-no need to allocate

place at site for storage of cement, aggregate, sand.

 It minimizes cement wastage due to bulk handling and there is no dust problem
and therefore pollution-free.

 Save contractor’s time, usage of Labor’s energy to mix concrete and also saves
project time.

 Multi transportation of raw materials.

 Creates a clean pollution free (noiseless and dust less) environment.

DISADVANTAGES :

 Double handling results in additional cost and losses in weight.

 Requirement of godowns for storage of cement and large area at site for storage
of raw materials.

 Aggregate get mixed and impurities creep in because of wind, weather and
mishandling at site.

 There are always the 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.

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11. Industry Standards for Truck Mixers:

 Each batch of concrete must be mixed not less than 70and not more than 100
revolutions of the drum.

 Agitating speed is usually about 2 to 6 rpm.

 Mixing speed is generally about 8 to 12 rpm.

 Concrete is to be delivered and unloaded within 1 to 2 hours or before the drum

revolved 300 times after the introduction of water to the cement and aggregate.

Ordering of RMC:

 Amount or structural dimensions.

 Cement content (bags per cubic yard).

 Water-cement ratio.

 Strength of concrete needed.

 Type of aggregate

 Size of aggregate.

 Slump

 Admixtures (type and amount)

 Time of delivery.

Clean-up Equipment:

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 Clean all the tools that comes in contact with concrete.

 Wash any mud or dirt from the frame of the mixers.

 Rinse out the interior of the drum thoroughly.

 Clean any hardened concrete from tools or equipment by scraping and wire
brushing to remove.

 Hammering on a mixer to loosen concrete is not advisable because this will

damage the drum or the mixer.

 Always clean the mixer as soon as possible after use.

 A weak vinegar solution (10% acetic acid) is sometimes used to clean the cement
film off the exterior of mixers. Areas cleaned in this manner should be relaxed to
protect the mixers.

12. 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).

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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)

13. STRUCTURES BUILT IN RMC

Structures Built With RMC in India:

 55nos. of flyovers in Mumbai.

 Mumbai-Pune expressway (95kms)

 9nos. of mini flyovers in Chennai.

 Super structures on station building of metro railway project at Chennai.

 M45 grade RMC using 30% OPC for worli out fall project in Mumbai.

 Tidal Park at Chennai.

 Many residential flats-houses in Chennai, Bangalore and Mumbai etc.

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Structures built with RMC in the World:

 Petronas Towers of Kuala Lumpur.

 World Trade Centre, New York, USA.

 Golden Gate Bridge, San Francisco.

 Changai International Airport, Singapore.

 Sydney Opera House, Australia.

 Euro Tunnel (UK/France)

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PETRONAS TOWERS OPERA HOUSE

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TALOJA FLYOVER

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14. 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 canters. 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 saleability 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)

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15. GENERAL PRECAUTIONS:  

AT THE TIME OF CASTING:

 Check and ensure that the concrete cover blocks are intact and not disturbed
during concreting operations.

 Closely supervise the proper batching of ingredients, water content, mixing and
testing of fresh concrete in case of concrete made at site. However, for RMC this
aspect is taken care of as the degree of quality control is very high.
 Beams should be cast first in layers and properly compacted with vibrators.
 One carpenter & helper should be present below slab shuttering to ensure that
props are not disturbed and shuttering remains intact in position during & after
concreting.
 One bar bender should be present to ensure that no displacement of steel
reinforcement takes place.
 Do not allow very smooth finish to concrete slab. Do not allow spunk ling of dry
cement for finishing, avoiding micro shrinkage cracks.
 Ensure that top reinforcement bars (for negative movement) are not disturbed
during concreting by placing the chairs firmly and properly.
 Avoid formation of cold joints in the slabs.
 For concreting during summer season, cover freshly casted slab with moist
gunny bags after 4-5 hours of casting.
 In case of rain, high winds and hot temperature cover the slab with tarpaulin to
protect it from getting damaged.
 Do not allow drastic drying of green concrete to avoid plastic shrinkage cracks.
 Closely supervise the compaction and finishing process of concrete.

AFTER CONCRETING OF SLAB:

 Deshuttering of vertical sides of beams, columns only after 24 hours.

 Cursing of slab for 14 to 20 days depending upon the type of structure.
 Deshuttering of slab after 7, 10 or 15 days depending upon span of slab and type
of cement used.
 Deshuttering of beams after 14 or 21 days depending upon span.
 Checking all spots of honeycombing and finishing which rich cement sand
mortar.

BEFORE CASTING OF SLAB:

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 Check concealed electric conduit work, junctions and all electrical points, MS
boxes as per electrical layout plan.
 Check the reinforcement and obtain approval from RCC consultant.
 Check the standby arrangement for water in case of electricity failure
 Decide the position of concrete joints in case of a big slab after consulting the
RCC consultant.
 Ensure removal of wooden pieces, paper, etc. from slab/beam before casting
 Ensure that shuttering and scaffolding is firm and proper
 Ensure all joints in formwork are properly sealed to avoid slurry leakage. Instead
of using mud, jute, paper, etc. it is desirable to use putty of used grease and
cement (50:50). It effectively seals joints and remains intact during vibration of
concreting. Strip of aluminum foil to cover gap can also used.
 Make arrangement of wooden planks and steel chairs and place them on slab for
labor movement. Do not allow labour to directly walk on reinforcement.
 Check if vibrator is in working condition and adequate labour is available.
 Sprinkle little water over shuttering just before placing the concrete.
 Ensure sufficient light arrangements in case of late evening concreting and
provide safety measures.

Ensure that concrete cover blocks of proper size are provided at site as per requirements
of BIS standards.

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Ready Mix Concrete Truck

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16. CONCLUSIONS

 In future of RMC in India is very bright. The allotment of land at confessional

rates and availability of water, electricity and other infrastructure and removal of
sales tax by government would accelerate the RMC industries in India.

 The RMC can be suitably produced to ensure quality in concrete construction.

 Three-way interactions between RMC manufacturers, users of RMC, research

and academic institute is essential to develop RMC’s using indigenous materials.

 The successful running of a RMC concern depends upon the regular supply of
materials, efficient operation of the machinery, plant and the production
economically of concrete guaranteed strength and quality.

 For successful operation of RMC.s in India, a suitable scale of production should

be adopted.

 The tests which are required to arrive at the correct proportions of a concrete mix
and to ensure that strength requirements are being compiled with, are simple and
do not require elaborate laboratory equipment.

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 If in addition, care taken to see that the static and mobile plant machinery are
maintained in a sound working condition so that break-downs, if any, are rare
occurrences.

17. REFRENCES

 “RMC in India” (June 2001), Civil Engineering & Construction Review.

 A.M Neville, Properties of Concrete.
 M.S Shetty, Concrete Technology.
 National Seminar on Advances in Special Concretes.
 Reference issued by Concrete Association of India.
 Zacharia, G (1985) Ready mixed concrete, Indian Concrete Institute,
Madras.
 Kaushal Kishore (June 2001), “RMC: Some Technical Aspects”, Civil
Engineering & Construction Review.
 “RMC on the move” (Oct. 2003), Ambuja Technical Literature, Vol. No. 90.
“Mechanisations of concreting, Part I- Batching, Mixing & Transporting” (Dec.

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1996),
 www.scaletron.com, mariane@scaletron.com
 www.worldofconcrete.com
 ASTM C 94, Specification for Ready Mixed Concrete, ASTM, West
Conshohocken,
Pennsylvania, www.astm.org

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