Rmc plant


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Rmc plant

  1. 1. 1.0 Introduction:-• Few things are more aggravating to produce on a worksite than concrete. Bags of cement, sand, aggregate (gravel) and 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 and heavy ingredients have been loaded into the hopper, one small error in the wet/dry ratio can render an entire batch of concrete unusable. One common solution to this messy and time-consuming problem is “READY MIX CONCRETE”• 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 1
  2. 2. 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. 2
  3. 3. 2.0 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. 3
  4. 4. 3.0 Scope of Ready Mixed Concrete 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:-1. Major concerting projects like dams, roads, bridges, tunnels, canals etc.2. for concreting in congested areas where storage of materials is not possible.3. Sites where intensity of traffic makes problems.4. When supervisor and labour staff is less.5. To reduce the time required for construction etc.6. Huge industrial and residential projects. 4
  5. 5. 4.0 Details of Plant Visited Site:- • Address of the Plant Visited Site: - Innovative Infrastructure, Ready mixed concrete, Opp. Ekta Hotel, Sarkhej, Ahmedabad.Location: - Key Plan 5
  6. 6. • Time of Establishment: - 02/06/2006• Authority People: - (1) Mr. Harishbhai Gohil (2) Mr. Natubhai Gohil• Area of Plant: - Minimum area is 3500 yard• Timing: - 24 hours working• Human Resource Management: - Workers 36 Engineers 20 Total 56Financial Aspect:-• Investment Cost: - About 8 to 9 Crore 1 Crore Plant 75 lakh batching Plant 25 lakh silos 36 lakh of Trucks 1 Truck x 22 times 4.5 Crore of Land • Maintenance Cost: - 65 rs/ m3 6
  7. 7. • Charges to the Clients: - Grade Rate/ m3 M 7.5 2600 rs/m3 M 10 2900 rs/m3 M 15 3500 rs/m3 M 20 4000 rs/m3 M 25 4300 rs/m3 M 30 5000 rs/m3• Recent Project:- Project name • Tesla Pronestyl, Shantipura Choki • Per Day 200 m3 Concrete Supplied • About 5 km from Plant• Cost of Raw Material:- Material Rate/tonne From Sand 224 rs/tonne Sabarmati Aggregate 700-740 rs/tonne Surendranagar 7
  8. 8. 5.0 Flow Chart of Manufacturing Process:- • Inert raw material namely fine aggregate and coarse aggregate are stored in bins, where as cement is stored in hopper. • Water and admixtures are stored in tanks. The inert raw materials are fed to the batching plant mixer by means of an aggregate belt conveyor. • The required quantity cement is extracted by screw conveyor and fed into the mixer. • Water and admixture are pumped into the mixer bye weight. After the mixing is completed, the ready mixed concrete is discharges into the transit mixer which can then transport the concrete to the construction site. • All these above operation are controlled by a computer housed in the control room of the batching plant. 8
  9. 9. Manufacturing process of Concrete in R.M.C. Plant Raw Material used to produce Concrete• Ready-mix concrete is made from cement, aggregate and water.• Aggregate make up majority of the concrete’s volume and the cement provides resistance.• Additives are incorporated into the mix to ensure particular properties such as improved durability or shortened hardening times.• During the mixing phase, we control every step to ensure quality and uniformity.Raw Materials are:- 1. Water 2. Additives 3. Cement 4. Aggregate 5. Air 9
  10. 10. Aggregates • Aggregates, which make up roughly 60% to 75% of ready mix concrete’s volume, are obtained from quarries and aggregate banks. Additives• Additives are solid or liquid chemical substance that can be added to ready mix concrete before or during preparation.• Most commonly used additives either improve a hardened concrete’s durability or reduce a concrete’s water content in an effort to shorten setting times. 10
  11. 11. Water• This is the mix’s vital fluid sets off a chemical reaction when it comes into contact with the cement.Cement• No others material rivals cement’s important in the mix; it’s the ingredient that gives concrete its strength.• The most widely used cements are gray Portland type 1 and Pozzolona Portland type 2. 11
  12. 12. Concrete mixing• During the mixing phase, the different components come together to produce a uniform mass of concrete.• Mixing time is registered from the movement material and water is poured into the cement mixer, and it begins rotating. Ready to use for site• While transporting concrete to a site, the cement mixer never stops revolving at a speed of two to six rotations per minute. 12
  13. 13. 6.0 Equipment Required in R. M. C.:- Following are the equipment’s required in R.M.C1. Batching plant2. Silos3. Belt Conveyor4. Transit mixerBATCHING Batching plants are classified as1. Manual2. Semiautomatic3. Fully automaticStorageStorage of the raw materials is done by following methods: -Inline BinsInert raw materials like fine & coarse aggregates are stored in bins called as “Inline Bins” wherethe trucks carrying fine & coarse aggregate can dump the material easily. The aggregatesrequired are fed by the means of aggregate belt conveyer. On the aggregate belt conveyer theaggregates are weighed automatically by means of computer form the computer room presentson the plant. 13
  14. 14. Batching plants are classified as:-1. Manual Batching Plant:-Place of Origin China (Mainland)Model Number HZS50Motor Power 5.5kwMixing Power 37kwCharging Capacity 1000LSpeed of Mixing Drum 28r/minWater Supply Mode AutomaticWorking Cycle Period 72sDischarge Way manualOutline Dimension 22.2m x 2.4mProduction 50m3/h 14
  15. 15. Conveyor Capacity 400 t/h• MixerType JSJ1000Power 2×18.5 KWOutput 1 m3Grain Size ≤60 mm• BatcherHopper Capacity 13 m3Hopper Quantity 3 15
  16. 16. 2. Semiautomatic Batching Plant:-• SpecificationsConcrete stirring station, our leading product, is formed by semiautomatic concretemanufacturing equipmentPlace of Origin China (Mainland)Model Number HZS150 16
  17. 17. • Complete PlantPeak Capacity 150 m³/hCycle Time 60 sDimension 43.5 X 24 X 18.7 mInstalled Gross Capacity 260 KWStandard Discharge Altitude 4m• Batching PartModel JS3000• Feeding PartModel PLD4800• Pneumatic SystemAir Compressor Model 1.8-7Rated Air Discharge Rate 1.67Power of Motor 15 KW 17
  18. 18. 3. Automatic Batching Plant:-Place of Origin China (Mainland)Model Number HZS90• SpecificationsCapacity 90m3/hMixing system win-shaft concrete mixerAggregate feeder Belt conveyorDischarging height 3900mm 18
  19. 19. • Batching PlantDischarging volume 1500LCharging volume 2250LMixing cycle 60sMax. mixing size Φ100/80mm• Aggregate batching machineStorage bins quantity 4 sortsAggregate scale hopper 2400LAggregate feeding to mixer by Belt conveyor• Cement storage and feeding systemCement silo capacity 60t/80t/100tScrew conveyor diameter Φ273mm 19
  20. 20. 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. 20
  21. 21. Technical Specifications of Silos1. 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. 21
  22. 22. 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. 22
  23. 23. • 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. 23
  24. 24. Transit Mixer:-• Specifications of MixerNominal Capacity 6 m3Geometric Volume 11700 litersWaterline Volume 7100 litersFilling Ratio 51.3%Rotation Speed 0-14 rpmLength of Mixer 5743 mmWidth of Mixer 2485 mmDrum Thickness 5 mmWater tank Capacity 450 24
  25. 25. 7.0 Merits & Demerits of Ready-Mix Concrete:- Merits of Ready-Mix Concrete • A centralized concrete batching plant can serve a wide area. Site Mix trucks can serve a larger area including remote locations that standard trucks cannot. • The plants are located in areas zoned for industrial use, and yet the delivery trucks can service residential districts or inner cities. Site Mix trucks have the same capabilities. • Better quality concrete is produced. Site Mix can produce higher compression strength with less water than standard batching methods. • Elimination of storage space for basic materials at site. Standard Batch plant need more room for their operation than Site Mix trucks. • Elimination of procurement / hiring of plant and machinery • Wastage of basic materials is avoided. With a Site Mix truck, there is less waste and wash out. This is better for the environment. • Labor associated with production of concrete is eliminated. It takes more people to operate a standard batch plant than a Mobile Mix truck. • Time required is greatly reduced. One Mobile mix truck can produce 8 yards of concrete in 8 minutes. It can also operate continuously without needing to be moved away from the pump truck. One Mobile mix truck can produce 460 yards of concrete in an 8 hour shift. Where standard trucks must stop and move off the pump to bring in the next truck. So to deliver the same amount of concrete it will take nearly 3 more hours with a standard truck. This will increase labor cost. Demerits of Ready-Mix Concrete • The materials are batched at a central plant, and the mixing begins at that plant, so the travelling time from the plant to the site is critical over longer distances. Some sites are just too far away, though this is usually a commercial rather than technical issue. • Generation of additional road traffic; furthermore, access roads, and site access has to be able to carry the weight of the truck and load. Concrete is approx. 2.5tonne per m³. • This problem can be overcome by utilizing so-called minimix companies, using smaller 4m³ capacity mixers able to access more restricted sites. • Concretes limited time span between mixing and going-off means that ready-mix should be placed within 10 minutes of batching at the plant. • Modern additives modify precisely that time span however, the amount of additive added to the mix is very important. 25
  26. 26. 8.0 Manufactures in India:- 1. APOLLO INFRATECH PVT. LTD. …………...MehsanaFirm type Private LTD.Level to expand NationalProducts/Services Concrete batching plant, Transit mixersProduction 20cum/hr., 30 cum/hr.,40cum/hr.,60cum/hr.,90cum/hr.Depreciation 15 years(12,000 hours) 2. NILKANTH ENGINEERING WORKS.......... AhmedabadFirm type ProprietorshipLevel to expand InternationalProducts/Services Mobile concrete batching plant, Ready mix concrete batching / mixing plantProduction 15cum/hr., 20 cum/hr., 30cum/hr., 50cum/hr.,Depreciation 15 years(12,000 hours) 26
  27. 27. 3. UNIVERSAL CONSTRUCTION MACHINARY & EQUIPMENT ....PuneFirm type PrivateLevel to expand InternationalProducts/Services Batching plant, Concrete mixer, earth compacter,Production 45cum/hr., 60 cum/hr., 80cum/hr., 120cum/hr.,Depreciation 10 o 15 years 4. MACONS …………………AhmedabadFirm type PrivateLevel to expand NationalProducts/Services Batching plant, Concrete mixer, Transit mixer, dumper, Concrete paver, Wet mixed macadam,Production 20cum/hr., 24 cum/hr., 30cum/hr., 36cum/hr.,Depreciation 10 to 15 years 27