NATIONAL INSTITUTE OF CONSTRUCTION

MANAGEMENT AND RESEARCH

- SITE VISIT REPORT -

DATE: 16 OCTOBER 2019

SAI READY MIX COCRETE

ACM 33 | SECTION 3 | GROUP 5 | TEAM A

NAME ROLL
NO.
MR. PADGHAWALA HUSSAIN YUNUS AP19217
MR. UPPALAPATI SHANMUKHA KRISHNAM RAJU AP19218
MR. KARDA BHARAT RAJKUMAR AP19219
MR. RUPARELIA GOPAL ASHOKKUMAR AP19220
MR. PRAJWAL ALABURU AP19221
MR. NAYAK SARTHAK AP19222
MR. RATH SAMBHIT SWARUP AP19223
MR. JADHAV SIDDHARTH PRAKASH AP19224
MR. BHARATH SIMHA REDDY AP19225
MR. MALAY P. SHAH AP19226
MS. SIKKEWAL NALINI AP19227
MR. CHEVALE RUSHIKESH SANDIPAN AP19228

FACULTY CO-ORDINATOR: PROF. DEEPAK M. D.

AIM:
To study the working of Ready-Mix Concrete (RMC) plant.

PURPOSE OF VISIT:
The main objective behind the visit was to get some knowledge about the concrete
technology. The whole process was elaborated during the visit and various components
which are been used in RMC plant was explained by in charge.

INTRODUCTION:
Ready-mix concrete is concrete that is manufactured in a batch plant, according to a set
engineered mix design. Ready-mix concrete is normally delivered in two ways. First is the
barrel truck or in–transit mixers. This type of truck delivers concrete in a plastic state to the
site. Second is the volumetric concrete mixer. This delivers the ready mix in a dry state and
then mixes the concrete on site. Batch plants combine a precise amount of gravel, sand, water
and cement together by weight, allowing specialty concrete mixtures to be developed and
implemented on construction sites.
Ready-mixed concrete is used in construction projects where the construction site is not
willing, or not able, to mix concrete on site. Using ready-mixed concrete means product is
delivered finished, on demand, in the specific quantity required, to the specific mix design
required. For a small to medium project, the cost and time of hiring mixing equipment,
labour, plus purchase and storage for the ingredients of concrete, added to environmental
concerns may simply be not worth it when compared to the linear cost model of ready-mixed
concrete, where the customer pays for what they use, and lets someone else do the work up to
that point. For a large project, outsourcing concrete production to ready-mixed concrete
suppliers means delegating the quality control and testing, material logistics and supply chain
issues, and mix design, to specialists who are already set up for those tasks, trading off
against introducing another contracted external supplier who needs to make a profit, and
losing the control and immediacy of on-site mixing.

BACKGROUND:
In India, the concept of ready-mix concrete plants was launched about two decades ago. Lack
of proper manuals, higher initial investments for installation of automatic batching plants and
awareness were the major causes that led to an initial set back of the ready-mix concrete. In
the present era, rapid urbanization has commercials like shopping malls, retail units,
multiplexes and several other real estate projects have largely increased the demand of good
quality concrete is also one of the basic requirements to make the structures earthquake
resistant.
Problems in availability of land in urban cities particularly the metro and mega cities have
increased the need for vertical expansion due to restrictions and constraints in the horizontal
expansion. Thereby construction of tall structures has become an essential requirement of
urban cities. Thus, in course of time awareness of the advantages of using ready-mix concrete
pant and realization of the fact that the conventional concrete may result in higher life cycle
cost due to higher maintenance costs made the construction industry to adopt ready-mix
concrete plant as a better option economically and qualitatively. But in India about 9% of the
total cement produced is utilized in ready-mix concrete plant against 80% of the cement
produced being utilized in UK and US.

MATERIALS AND METHODS:

A ready-mix concrete plant is a set-up of whole equipment that combines various ingredients
to form concrete. Some of these inputs include water,
air, admixtures, sand, aggregate (rocks, gravel, etc.), fly ash, silica fume, slag, and cement.
Raw materials include:

 In-house production of 10-20 mm crushed sand using cone crusher

 OPC 53 - Coromandel King
 Fly ash from Parli
 Admixtures for 3 hour retaining time, self-compacting concrete, strength gain
- BASF (naphthalene base)
- Master Reobuild 8501
- Master Ease 3811
- SIKKA-4233 NS (SikaPlast)

Different apparatus used for various tests:

1. Hot air oven – to measure moisture content in crushed sand
2. Vicat apparatus – to measure consistency and setting time
3. Picnometer
4. Sieve analysis
1. Passes through 4.75 mm is considered to be fine aggregate
2. Retains above 4.75 mm is considered to be coarse aggregate
5. Impact value of aggregate
6. Flaky and elongation test
7. Compatibility test of cement and admixtures
8. CTM (CP = 2000 kN) – to measure 7, 28 days compressive strength
9. Curing – 3, 7, 28 days

There are 3 methods of production:

 Transit or Truck mixing
 Central Mixing
 Shrink Mixing
RESULTS AND DISCUSSION:

SAI Ready-mix Concrete Plant located at Punawale, Pune belongs to Sai Group of
Companies. They manufacture various grades of concrete from M 7.5 to M 60 as per clients’
requirements.

 The entire set-up cost of the plant was Rs. 10 crore, the plant cost being Rs. 75 lakhs.
 The capacity of the batching plant is 60 m3/hr with batch size being 1 m3.
 The production cost of the plant is MOM: Rs. 1000 per m3 excluding the labor cost.
 The fly ash being a waste material costs around Rs. 1.6 per kg and Master Reobuild 8501
admixture costs Rs. 40 per kg.
 It costs around Rs. 4200 per cum to manufacture M 20. However, on the site it costs
around Rs. 5000 per cum.
 Total mixing time for one batch of concrete is 25 seconds.
 Total time taken in production and placing of concrete in one transit mixture is
approximately one to one and a half hours while the same amount of concrete if produced
on site will take around 3-4 hours.

APPLICATIONS:

 Consistent mix design for large scale agricultural projects including single and continuous
pours.
 Used in major concreting projects like roads, damns, canals, bridges, tunnels, etc.
 Huge residential and industrial projects.
 For concreting in congested areas where storage of materials and disposal of waste is a
problem.
 Used in site conditions where staffing requirements are difficult to meet.
 For projects where speedy completion is an added advantage.

CONCLUSION:

While the presence of ready-mix concrete in India has been growing steadily over the past
few years, it only accounts for about 9% of cement consumption compared to other
developed countries wherein, nearly 80% of cement consumption is in the form of RMC.
Cyclical downturns in construction activity driven by slowing economic activity, deferearal
of infrastructure projects, policy hurdles and high interest rates has resulted in sub-dued RMC
demand growth in the last decade, affecting the industry in the terms of reduced production
volumes and cash flows.
 However, the RMC segment is expected to grow at a healthy rate in the next few years with
markets expecting to see a turnaround shortly and an increased emphasis on quality, safety
and speed within the Indian construction industry.

WORK DISTRIBUTION:

MR. PADGHAWALA HUSSAIN YUNUS Preparation of notes at plant visit

MR. UPPALAPATI SHANMUKHA KRISHNAM RAJU Report Preparation
MR. KARDA BHARAT RAJKUMAR Preparation of notes at plant visit
MR. RUPARELIA GOPAL ASHOKKUMAR Report Preparation
MR. PRAJWAL ALABURU Procedures in RMC Plant
MR. NAYAK SARTHAK Procedures in RMC Plant
MR. RATH SAMBHIT SWARUP Report Preparation
MR. JADHAV SIDDHARTH PRAKASH Introduction, Background
MR. BHARATH SIMHA REDDY Introduction, Background
MR. MALAY P. SHAH Report Preparation
MS. SIKKEWAL NALINI Preparation of notes at plant visit
MR. CHEVALE RUSHIKESH SANDIPAN Report Preparation
PICTURES AND PHOTOGRAPHS: