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1.0
INTRODUCTION
1.1
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.
Sometimes Materials such as water and some varieties of admixtures can be transit-mixed
(also known as Transit Mixture), that is they can be added to the concrete at the jobsite after it has
been batched to ensure that the specified properties are attained before placement. Here materials are
batched at a central plant and are completely mixed in the Batching Plant or partially mixed in
transit. Transit-mixing keeps the water separate from the cement and aggregates and allows the
concrete to be mixed immediately before placement at the construction site (Dry Concrete). This
method avoids the problems of premature hardening and slump loss that result from potential delays
in transportation or placement of central-mixed concrete.
Additionally, transit-mixing allows concrete to be hauled to construction sites further away
from the plant. There are several types of RMC plants varying in type of mixing and capacity of
concrete production.
These plants are generally available in capacities varying from 15 cum/hour to 200 cum/hour.
A typical RMC plant is shown here.
Figure : 120 CuM/hr RMC plant functioning in Bandra-Kurla Commercial complex, Mumbai
(Ambuja Cement Literature Vol. 90)
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Figure: Transit mixer in late 1940s and Concrete pump in late 1940s
(Ambuja Cement Literature Vol. 90)
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In India RMC was first initially was used in 1950 during the construction sites of Dams like
like Bhakra Nangal, 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. These plants were later allowed to
sell RMC to other projects also. Thus RMC was successfully established sometime after 1994 in
India.
RMC producers from outside India soon became interested in the Indian market and therefore
two very well known producers set their foot on the Indian soil i.e. Fletcher Challenge Ltd. from
New Zealand and RMC Ready Mix of UK.
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.
Metro
No. of
Plants
Capacity
(M3/hr)
Mumbai and
15
835
Bangalore
13
550
Delhi
11
660
Chennai
11
480
Hyderabad
350
Navi Mumbai
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aggregates this greatly helps in controlling the water to cement ratio (w/c) which results In
correct strength and durability.
RMC plants have proper facilities to store and accurately batch concrete admixtures
(chemical and mineral). To improve properties of concrete both in plastic and in hardened
stage this accuracy is useful.
In general, RMC plants have superior and accurate batching arrangements than the weigh
batchers used on site.
RMC plants have superior mixers than the rotating drum mixers generally used for mixing
concrete materials at site.
RMC plants have efficient batching and mixing, facilities which improve both quality and
speed of concrete production.
Temperature control of concrete in extreme weather conditions can be exercised in a much
better manner than done at site.
RMC helps encourage" mechanization and new technologies like pumped concrete bulk
transportation of cement production of self-compacting concrete and high strength high
performance concrete.
New materials like micro silica and fibers can be safely used in RMC which in conventional
concrete may pose problems.
Introduction of RMC improves the rate of supply of concrete in the formwork and thereby
automatically improves quality of formwork, layout of reinforcement steel and its detailing
and safety / strength of scaffolding and staging.
Constant control on aggregates for size, shape & grading not exercised on site.
Arbitrary batching and mixing by volume. Strict water-cement ratio not exercised.
Wastage of materials.
Retarded speed.
Manual operation.
Restricted spaces.
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Dust pollution
Noise pollution
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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.
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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.
Transit-mixing 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.
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b)
Batching arrangement
c)
d)
Mixing equipment
e)
Control systems
f)
g)
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 either installed on bulk carriers or a separate system available at the plant. If baggage
cement is used then the cement is loaded using a compressed air loader and a splitter unit.
Cement is weighed separately, and is transported from the silo into a mechanical or electro
mechanical weigher by means of a screw conveyor.
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 litronic MFM 85 moisture recorders (See Figure). These
recorders actually measure the moisture present in sand while the entire batch flows past. A
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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.
(a)
(b)
Figure: a) Compressed air cement loader and a splitter unit for loading cement packed in bags
b) Electromechanical weighing system used on modern batching plant for cement and
aggregates (Amubuja Cement Literature Vol.no.12)
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.
If concrete is very dry (stiff) the electrical resistance of the batch is measured and
if the concrete is wet the motor output is measured.
Accurate maintenance of the workability (consistency) of one cubic meter batch of concrete,
may depend on as little as one litre or less of water. It is scarcely conceivable that such a production
process could be controlled without actually measuring the workability and later correcting the
consistency.
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.
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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)
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ii) Storage in tall silo
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)
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 upto 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 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.
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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)
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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. Most of our indigenously manufactured plants
have free fall mixer. 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. The drum is loaded and
emptied by changing the direction of rotation, dropping a flap or tipping it.
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. These mixers have shorter mixing
time, give better homogeneity, consistency and strength to the concrete. Besides, they have better
facility for inspection. The following are the most common designs.
Figure: Cross sectional view of the single shaft compulsory power mixer.
(Amubuja Cement Literature Vol.no.12)
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Power Mixer
Capacity CuM
Output CuM/hr
Max.
(Compacted concrete)
(Compacted Concrete)
15
Single Shaft
120
--
150
Twin Shaft
3.5
120-150
--
190
Pan Type
120
--
64
--
140
64
If mixing is to be done on difficult concrete mixes, additional agitator is provided. The pan
type mixer with additional agitator or two agitators is claimed to be far in advance of any if other
mixer. Using additional agitators almost halves the mixing time. The additional agitator is driven by
a separate hydraulic system and can be set to any speed between 0 to 200 revolutions per minute.
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c) CONTROL SYSTEMS
Almost all imported production plants offer automatic systems for control functions. These
are required for better quality control, higher economy and superior working conditions.Fully
automatic plant control systems with multiple inputs for upto 120 mixes or template control system
are usually housed in a container or control room of the plant. Micro processor controlled
production plants represent the state of the art in the developed countries.
(a)
(b)
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)
These controls are operated from main desk. It also has material availability monitor and
printer plus an additional batching monitor. The entire plant can be operated by just one person.
Microprocessor control besides having fully automatic running facility offers number of additional
features like statistical data recording and processing, a printer unit, moisture adjustment
arrangement, customer address, memory etc.
All you need to do is push the required mix template into the slot and press the "start" button
and the control system does the rest. Aggregate and cement weighment, moisture correction, overrun
correction and additive weighment are done accurately to give the concrete mix of desired strength
and workability.
The built in trouble shooting programmes are most valuable and have a high reliability factor.
Even upto 1500 mixes of different types can be stored along with names and addresses of the
consumer and other data which is required to be stored in the computer for operation of the plant.
The mix data with quantity can be if required printed by the printer which is very useful for
invoicing the consumer for the concrete supplied to them.
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4 to 12 CuM
Mixer trucks
In India 4 Cum. Truck mixers are popular while the 6 and 7 Cum. Truck mixers
mounted on a 3 axle chassis enjoy a leading position on all world markets as it has a favorable
cost- performance ratio, large selection of chassis, good maneuverability and is more suited to
general batch size requirements.
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(a)
(b)
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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.
3.3 ADMIXTURES
RMC is generally transported to different construction sites and delivered with the help
of revolving type transits mixers. These sites are located at long distances and the concrete
delivered is workable, plastic and flowable. Experience shows that slump loss takes palce with
certain types of cement and to prevent this superpplasticiser are used.
RMC's often use admixtures formulated for special purposes like : (a) Improvement of
screeds, renders, mortars and concrete for increased water resistance and less risk-from
aggressive materials, (b) Integral waterproofers, (c) Foamed - for light weight insulation. void
filling and semi structural support, (d) Water repelling for semi-dry block concrete, (e)
Microsillica for use in high performance concrete. The introduction of microsillica was
observed to improve the pore solution chemistry of HPC. For higher replacement of cement by
silica fumes, the concentration of both K+ and OH- ions are substantially removed. However,
upto 20% replacement will not cause a drop in pH below that of saturated CaOH solution,
which is approx.12.5. Even at 30% replacement, pH does not drop below 11.5, which is
considered to be a threshold value for maintaining a good passivity of embedded steel.
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Reliability of the plant and transit mixers for consistent and continuous concrete supply as per
requirement.
Mode of operation of plant should preferably be fully automatic and not manual.
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Time likely to be taken by transit mixers from plant to site and back.
Adequacy of formwork to take the hydrostatic pressure and adequacy of loading on propping
system to match the speed of placing.
Adequacy of manpower and equipment for placing, compacting, finishing and curing of
concrete.
Proper approach for transit mixers free from all encumbrances ego water logging, material
stacking etc.
Proper precautions required to be taken to ensure that concrete from the transit mixer is
unloaded at the fastest possible speed does not take more than 30 minutes.
If pumping is proposed, the location of the pump should be approachable from both sides.
Proper co-ordination between the RMC supply and placing and compacting gangs.
Ensure that water addition or chemical admixtures are not added during transportation by
RMC unauthorized persons and without the knowledge of the site in charge of the
consumer.
Continuous and steady supply at site and speedy unloading of the Monitor speed and progress
of placing to avoid formation of cold joints transit mixers.
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Monitor placement of concrete at the closest possible point to its final location.
Arrange for curing as soon as finishing is completed. This is specially required in case of
slabs, pathways and roads in hot/warm weather.
Retempering should be prohibited as experiments shows the addition of water to RMC truck
at the construction site may result in substantial reduction in strength. The reduction in
strength was found to be proportional to the increase in slump. Large increase in slump
means higher reduction in strength. When the amount of water added is not controlled,
reduction of strength may be as high as 35%. In cases where controlled amount of water is
added to restore the slump within the specifications limits (100 25 mm), the reduction of
strength may be below 10%.
4.6
Insistence on use of cement and admixtures of specific brands: This selection should be
left to the RMC supplier as they have to decide this based on the comparability study.
Inappropriately low water to cement ratio. This should be left to the RMC supplier or
alternatively high strength of concrete specified.
Insisting on Indian Standard method of concrete mix design: It must be understood that
IS 10262 (1982) only gives guidelines on design of concrete mixes. It does not cover
high strength cements now available and does not cater to effects of admixtures. It also does
not recommend changes necessary for RMC and pumpable concrete mixes. Concrete
mixes designed by this method are generally found to be non-cohesive and require
higher cement contents (uneconomical). The option of concrete mix design should be and
must be left to the RMC supplier.
Frequency of testing: This is often changed by the consumer than that specified in clause
6.3.2 of IS 4926 (2003). However, this needs to be mutually discussed and finalised prior to
placement of order.
Fixed slump insisted upon: Many a times fixed slump value is insisted upon by the
consumer. This is practically not possible. Variations are likely to occur and should be
within the limits say 25 mm as stated in clause 6.2.1 of IS 4926 (2003).
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instead of characteristic strength required without mentioning the accepted failure rate or
standard deviation.
4.7
Concrete Field strength should not be less than Target strength: Such a specification that
the field strength should not be less than the target strength should not be less than the target
strength belies the understanding of the definition of characteristics strength. If the
requirement is for an M30 grade concrete, then the field strength of concrete should not be
less 30 N/mm2 within a confidence limit of 95%. If the specification insists on target strength
to be achieved in the field as well, then the concrete requested automatically becomes M39 or
its equivalent. This makes the concrete unnecessarily expensive.
RMC cost is likely to be slightly higher than site produced concrete of the same quality. This
may be mainly due to sales taxes. However, to some extent if RMC consumer has no
objection to addition of flyash or ground granulated blast furnace slag of required quality and
consistency then perhaps the cost becomes more competitive with site produced concrete.
RMC plants having accurate computerised batching and excellent mixing facilities can
produce good quality RMC if they are careful in selecting the mineral admixture.
Delayed payments and long credit period insisted upon by consumers affect their cash flow.
RMC plants in cities are not permitted to be installed in residential zones. This results in their
installation nearly 10-20 kms. away from their potential consumers located in residential
zones.
High cost of the plant and equipment results in high capital costs. However, many multinationals have started producing plant and equipment in our country. Hence costs have
reduced. However, one has to be careful as quality of performance has dropped in
comparison with equipment directly imported from countries like Germany.
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. As new plants come up, skilled workers keep changing jobs for better prospects.
Non availability of consistent and good quality aggregates, mineral admixtures etc.
Non-availability of bulk cement supply in most of the cities where RMC is marketed.
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Stipulations of pollution control board causing difficulty to obtain license for running RMC
plant. Such clearances are not required if similar plants are installed on the construction site
itself.
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 to take proper vertical loads and hydrostatic pressures,
due to faster rate of supply and placing is often not taken care of at sites receiving concrete.
Reinforcement layout and planning of placement, compaction and curing must be properly
organised at site to suit the speed of supply and placement of RMC.
Concrete cube failures and their acceptance criteria due to site inadequacies or
sampling should not be attributed to RMC supplier.
Plastic shrinkage cracks due to inadequate curing at site often results in blaming the RMC
supplier.
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CONCLUSION
Conventional approach to durable concrete structures, namely specifying maximum
water cement ratio, minimum cement content and cement type, is now always satisfactory,
especially under aggressive environmental condition. Site manufactured concrete cannot assure the
same quality of concrete and that from controlled ready mix batching plant backed by advanced
technology and project management. The advantages of RMC are particularly evident in
construction projects with aggressive exposure conditions.
Ready mix concrete has gained acceptance in Indian industry due to several advantages
including quality control and overall economy. RMC plant are proliferating, especially in urban
regions, not only because of the space restrictions around construction site but also due to the
realisation of the advantages by engineers and construction industry.
That concrete quality produced in RMC plant is highly consistent with low deviation
order. It provides a high degree of overall strength of hardened concrete and the performance of
the structure at a later date. RMC operations are highly mechanized and fully controlled
through electronic controls and hence reduce the probability of errors in various operations. It
is also environment friendly and brings down pollution due to dust at construction can also be
accelerate with the use of RMC. The use RMC in civil construction is widely adopted through
out the world. The beginning made in India is in tune with the developments outside and RMC
uses provide numerous benefits to the consumers.
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REFRENCES
Kaushal Kishore (June 2001), RMC: Some Technical Aspects, 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
Abdulrahman M. Alhozaimy
and Abdulaziz I. Al-Negheimish (Dec 2002),
RETEMPERING OF READY-MIXED CONCRETE IN RIYADH, SAUDI ARABIA,
Civil Engineering Department, King Saud University.
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