RMC PLANT-

CLASSIFICATION,OPERATION &
COST ANALYSIS OF PRODUCTION

SUBMITTED BY
SAYANTAN DAS
ROLL NO: 1854003
BRANCH: C.E.M
 INTRODUCTION
• 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 to a set recipe or as per specifications of
the customer, at a centrally located batching plant.
• It is 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 truck, which keeps the mixed concrete in
correct form. In the case of the centrally mixed type, the drum carrying the concrete
revolves slowly so as to prevent the mixed concrete from "segregation" and prevent its
stiffening due to initial set.
• 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 80 meters.
• RMC is preferred to on-site concrete mixing because of the precision of the
mixture and reduced worksite confusion. It facilitates speedy construction through
programmed delivery at site and mechanized operation with consequent economy.
• It also decreases labour, site supervising cost and project time, resulting in
savings. Proper control and economy in use of raw material results in saving of natural
resources. It assures consistent quality through accurate computerized control of
aggregates and water as per mix designs. It minimizes cement wastage due to bulk
handling and there is no dust problem and therefore, pollution-free.
• Ready mix concrete is usually ordered in units of cubic yards or meters.
It must remain in motion until it is ready to be poured, or the cement
may begin to solidify. The ready mix concrete is generally released from
the hopper in a relatively steady stream through a trough system. Workers use
shovels and hoes to push the concrete into place.
• Some projects may require more than one production run of ready mix
concrete, so more trucks may arrive as needed or additional batches may be
produced offsite and delivered.
• However there are some disadvantages of RMC to, like double handling,
which results in additional cost and losses in weight, requirement of god
owns for storage of cement and large area at site for storage of raw materials.
• Aggregates get mixed and impurities creep in because of wind, weather and
mishandling at site. Improper mixing at site, as there is ineffective control
and intangible cost associated with unorganized preparation at site are
other drawbacks of RMC.
• There are always 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.
• The first ready-mix factory, which was built in the 1930s, remained in a
standstill position till 1960s, but continued to grow since then.
 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, a 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. In Europe in 1997
there were 5850 companies producing a total of 305 million cusecs
of RMC. In USA by 1990, around 72% (more than 2/3rd) of cement
produced was being used by various RMC plants. In Japan first RMC
plant was set up in 1949. By 1992 Japan was the then largest
producer of RMC, producing 18196 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.
 DEVELOPMENT IN INDIA
• In India RMC was first initially was used in 1950 during the construction
sites of Dams like likeBhakraNangal, 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.
• The first concrete mixed off site and delivered to a construction site was
effectively done in Baltimore, United States in 1913 just before the First
World War.
• The increasing availability of special transport vehicles, supplied by
the new and fast - growing automobile industry, played a positive role in
the development of RMC industry.
 SCOPE OF RMC PLANT
• Long, Long years ago, their where simple houses but in
21st century we can see houses constructed in R.C.C.
• Therefore concrete got more importance than any other
construction material. So the use of concrete is increasing
day by day.
• For construction most of the contractors and builders have
to collect the raw materials required for the construction
before starting actual works. These materials should be
stored at the site properly. This technique can be possible
when there will be more empty space at the construction
site which is not possible in congested areas. At this time
there is one solution to overcome all these problems that
is nothing “READYMIX CONCRETE”.
By using R.M.C we can save time and money
required for the labours. In following places ready
mix concrete can be used:-
• Major concerting projects like dams, roads,
bridges, tunnels, canals etc.
• For concreting in congested areas where storage
of materials is not possible.
• Sites where intensity of traffic makes problems.
• When supervisor and labour staff is less.
• To reduce the time required for construction etc.
• Huge industrial and residential projects.
FLOW CHART OF MANUFACTURING PROCESS
MANUFACTURING PROCESS OF
CONCRETE IN RMC PLANT
RAW MATERIALS UED TO PRODUCE CONCRETE
 EQUIPMENT REQUIRED IN RMC
Following are the equipment’s required in R.M.C:
1. Batching plant
2. Silos
3. Belt Conveyor
4. Transit mixer
5. Aggregate bins

BATCHING:

Types:

1. Manual
2. Semiautomatic
3. Fully automatic
• Storage:
Storage of the raw materials is done by following
methods: -
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
material easily. The aggregates required are fed by
the means of aggregate belt conveyer. On the
aggregate belt conveyer the aggregates are weighed
automatically by means of computer form the
computer room presents on the plant.
 TYPES
• Manual batching plant:
• Semiautomatic Batching Plant:-
• Automatic Batching Plant:-
• Storage silos:-

• The requirements of
construction, engineering and
process industries come up with
an exclusive range of Cement, Fly
ash, Limestone Silos that is
manufacture from very high
quality Structural raw material.

• Storage of Cement, Fly ash,

Limestone silos are available in
3200mm to 3700mm diameter
and in the capacities of 50, 100,
200 and 300 tons.

• These silos are manufactured

in customized specifications as
per our client needs and
requirements.
• Technical Specifications of silos:-

1. Size - 3200mm Dia x 14 mts of Total Height.

2. Side shell thickness - 5mm/6mm thick of sail / VSP/ SSP / Standard
make of M.S plate.
3. Bottom cone - 6mm/8mm /10mm thick of above make as per
customer requirements.
4. Safety handrail on top will be provided.
5. Maintenance ladder with safety gage provided from bottom to top.
6. Bottom leg pipe should be ERW / Seamless type of TATA /
JINDAL Make Of heavy duty type.
7. Total silo should be two coat Red Oxide & Two coat finish enamel
paint or sand blasting as per customer’s requirements with Asian
paints or Berger make etc.
8. Provision will be provided for fixing of silo accessories.
9. Pipe line fittings will be provided with flanges for easy dismantling.
10. Double structure platform will be provided for fly ash storage
solos.
• Aggregate Feeding Belt Conveyors:-

• Manufactured and Supplied high

quality Aggregate Feeding Belt
Conveyors for Handling Sand, Jally,
Stones (Aggregates) to RMC
batching Plant.
• Capacities from 18 M3 to 300 M3 of
various types like Compartment, In
Line Silo, Four Bin Type, Mobile etc.
• Products are made by using very
high quality Structural raw material
make of VSP, SSP, TATA, JINDAL
STEELS; standard suppliers make for
drive unit, Belt etc.
• Also providing Heavy Duty Rollers
& Pulleys which ensures hassle
free and long life work
performance.
• These Aggregate Feeding Belt
Conveyors are widely available in
various specifications and
dimensions like 650 MM to 1200
MM wide.
• Ready-mix Concrete Portable Conveyors:-
For handling Ready Mix Concrete Output from batching plant to
Transit Mixer / Outer Area with stationary or Portable special Type
Belt Conveyors.
• Transit Mixer:-
 PRODUCTION EXPENSES
• Purchase of raw materials(Cement, Aggregates,
Admixtures)
• Salaries(Batch-man, Dozer Operator, Cement
unloader, Crane operator, Other yardmen)
• Rentals
• Utilities
• Depreciation
• Insurance
• Payroll Taxes
• Other Taxes
 DELIVERY EXPENSES
• Delivery expenses in a ready mix concrete
company operation consists of all expenses
incurred on the equipment involved in
deliveries, the salaries of all truck drivers and
mechanics ,Insurances, depreciation and repairs
on the equipment, insurance, truck licenses.
• Gas, Oil and Grease
• Tires and Tubes
• Repairs (tires and tubes)
• Truck and Automobile Licenses
 GENERAL ADMINISTRATIVE EXPENSE
• Salaries:
 Officer’s salaries.
 Sales salaries.
 Other: dispatcher, accountants, bookkeeper, or any other clerical
personnel that is required.
• Rentals
• Depreciation
• Payroll taxes
• Supplies
• Travel and Entertainment
• Telephone and Telegrams
• Advertising
• Automobile Expense
• Legal and Auditing
• Donations
COST ANALYSIS - 1
COST ANALYSIS-2
Merits of Ready-Mix Concrete
Demerits of Ready-Mix Concrete
 Manufactures in India
• APOLLO INFRATECH PVT. LTD.(Mehsana)

• NILKANTH ENGINEERING WORKS.(Ahmedabad)

• UNIVERSAL CONSTRUCTION MACHINARY & EQUIPMENT.(Pune)

• MACONS.(Ahmedabad)