2. Project Work
Batching Plant and RMC
Concrete
Acknowledgement:-
It would be our pleasure to express our sincere thanks to our guider Mr. Ankush Bhardwaj in
providing a helping hand in this project. His valuable guidance, support and supervision all
through this project titled:-
Batching plant and Ready Mixed Concrete
3. are responsible for attained its present form. We would like to thank our guider, colleagues
who have helped us in making this project successful one.
Abstract:-
Ready-mix concrete is ready to use material, with predefined materials mixtures of
cement, sand, aggregates and water. RMC is a type of concrete that manufactured in a
factory. According to as per the specifications or the requirements of the customers, then the
batching plant nearly located send or delivered the mixture to the working site with the help
of the truck mixers which are capable for mixing the concrete at the delivery time. This result
in allowing to developed the mixture on the construction time. 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.
4. This project deals with the advantages and disadvantages of the RMC plant and
quality control in the preparation of the concrete and the various tests conducts in before the
preparation of the concrete.
Content:-
Chapter 1:- RMC Plant
Introduction…………………………………………………………………
History of RMC…………………………………………………………….
RMC in India……………………………………………………………….
Objectives…………………………………………………………………..
Needs……………………………………………………………………….
Merits and demerits…………………………………………………………
Chapter 2:- Quality Control Lab
5. Introduction…………………………………………………………………
Needs……………………………………………………………………….
Advantages…………………………………………………………………
Materials used in quality control Lab………………………………………
Test conduct in Quality control lab…………………………………………
Chapter 3:- Test Conducts by Us
Fineness and Grading test for fine aggregates and coarse aggregates…….
Fineness of Cement………………………………………………………..
Specific Gravity of Fine aggregates and coarse aggregates……………….
Specific Gravity of Cement………………………………………………..
Water absorption of fine aggregates and coarse aggregates……………….
Bulking of sand …………………………………………………………….
Silt content ………………………………………………………………….
pH value of water……………………………………………………………
Slump test of Fresh Concrete……………………………………………….
Compressive strength of Hardened Concrete……………………………….
Chapter 4:- Mix Design……………………………………………………………………..
Chapter 5:- Conclusion………………………………………………………………………
6. Content for figures
Fineness…………………………………………………………………………….
Water absorption…………………………………………………………………....
Grading of aggregates
Fine aggregates………………………………………………………………
Coarse aggregates…………………………………………………………….
Bulking of sand………………………………………………………………………..
Silt Content…………………………………………………………………………….
Slump Test……………………………………………………………………………
Compressive Strength…………………………………………………………………
7. Content for tables
Grading of aggregates
Fine aggregates……………………………………………………………….
Coarse aggregates……………………………………………………………..
Water absorption……………………………………………………………………
Specific Gravity……………………………………………………………………
pH value………………………………………………………………………………
Compressive Strength of Hardened Concrete…………………………………..
8. Chapter 1
RMC Concrete Plant
Introduction of RMC Plant:-
Ready Mix concrete is a specialized material in which the cement aggregates and
other ingredients are weigh-batched at a plant in a truck mixer, before the 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 transport within the required
journey time. The RMC suppliers provides two services, firstly one of the processing the
materials for making fresh concrete and secondary transporting a product within a short time.
It is delivered to the worksite, often in transit mixers capable of mixing the
ingredients of the concrete just before the delivery of batch. This result in a precise mixture
allowing the concrete mixtures to 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.
The use of the RMC is facilitated through a truck-mounted boom-placer that can
pump the product for ready use at multi-stored constructional area. A boom placer can pump
the concrete up to 80meters.
Ready mix concrete is preferred to on-site concrete mixing because of the precision of
the mixture and reduced worksite confusions. It facilitates speedy construction through
programmed delivery at the site and mechanized operation with consequent economy. It also
decreases the labor, site supervision cost and the project time and results in saving of the
money from the estimated cost.
Ready mix concrete is usually ordered in units of cubic yards or meters.
Batching plant:-
A concrete plant is known as batching plant. Batching plant is a device that combines
various ingredients to from the concrete. Some of these inputs include sand, water,
aggregates, fly ash and cement.
There are two types of the concrete plants:-
1. Ready mix concrete plants
2. Central mix plants
9. 8
RMC (Ready Mixed Concrete):-
A concrete whose constituents are weight batched at a central batching plant, mixed
either at the plant or in the truck mixers and transported to the construction site and delivered
in a condition ready to use, is called as READY MIXED CONCRETE (RMC).
History of RMC Plant:-
RMC plant was introduced in Germany in 1903. In 1907, he has discovered that the
available time for transportation could be prolonged not only by cooling fresh concrete but
also by vibrating it during transportation. So this gives rise to a concrete which is made in the
off site.
The first concrete is the offsite concrete. United State in 1913 that increases
availability of special transport vehicles, supplied by the new and fast growing automobiles
industry.
The first concept of transit mixer was also born in 1926 in the United State. In 1939,
the first RMC was installed in United Kingdom and in 1933 first specifications on RMC
was published in United Kingdom.
By 1990 in the United State there were 3700 RMC produces and in Japan were
consuming nearly 70% of the total cement produced. In Malaysia RMC plants utilized nearly
16% of the total cement consumed in year 1990. In UK 43% of the total cement consumed is
being used by RMC plants.
RMC Plant in INDIA:-
In India RMC was initially was used in 1950 during the construction site of Dams like
Bhakra Nangal. At the construction the transportation of the concrete is done by manually or
mechanically.
RMC at Pune in the year 1991was established. Due to the problems this plant did not
survive for long and was closed. Within few years, in the year 1993 two RMC plants were set
up in the Mumbai to commercially sell RMC to the project were they were installed. RMC is
successfully established in 1994 in India.
As per the record up to 2003 there are around 76 RMC plant in 17 cities with a total
capacity of around 3875 Cum/hour producing 3.8 million Cum of concrete per year.
9
Objectives:-
The main objective to choose this project is that an engineer should have the
knowledge of advantages of RMC and disadvantages of the site mixed concrete. As RMC is
10. being widely used in bigger and medium size of the project today and the engineers should
know the techniques of the RMC and the operational work to ensure the quality of the work
and the site engineer should know what are the steps to be taken to check the concrete in
RMC, what is required to be specified for RMC, what is the information required to be
supplied by the RMC supplier, what checks are necessary by the consumer before ordering
RMC, what are the checks needed at the site and after to receipt of RMC.
Needs of Batching Plant:-
1. Required higher grades of concrete
2. Rapid development of infrastructure industry
3. Increase the demand of concrete
4. Timely supplied of reliable concrete
5. Better quality is procedure
6. Durable and affordable
7. Reduce the cost of labors
Merits and Demerits of ReadyMixed Batching Plants:-
Merits:-
1. Required higher grades of concrete
2. Rapid development of infrastructure industry
3. Increase the demand of concrete
4. Timely supplied of reliable concrete
5. Better quality is procedure
6. Durable and affordable
7. Reduce cost of labour
8. Eco-friendly
9. Time will be reduce
10. Wastage of basic materials is avoided
Demerits:-
1. Need large investments.
2. Not affordable for smaller project works.
10
3. Need effective transportation system.
4. If any problem occurs during transportation the dose of retarders is not gain
properly.
13. 13
Equipment’s and Components used in RMC
plant:-
Silos, containers, aggregates bins
Batching arrangement
Free fall mixer
Measuring and recording equipment’s
Mixing Equipment’s
1. Twin shaft mixer,
2. Tilt drum mixer
Control System
T
TRANSPORTATION EQUIPMENT’S
1. Transit Mixer
14. 14
Tests conduct in RMC batching plant or in
Quality Control Lab
Fine aggregates:-
1. Sieve Analysis or gradation of aggregates
2. Specific Gravity
3. Water Absorption
4. Bulking of sand
5. Silt Content
Coarse aggregates:-
1. Sieve Analysis or gradation of aggregates
2. Specific Gravity
3. Water Absorption
4. Impact Value
5. Bulk density
6. Flakiness Index
7. Elongation Index
Cement:-
15. 1. Fineness of cement
Water:-
1. pH value
Fresh concrete:-
1. Slump Test
Hardened concrete:-
1. Compressive strength
2. Flexure Strength
Chapter 3
Test Conduct by Us
Introduction
Test conduct by us:-
Fine aggregates:-
1. Sieve Analysis or gradation of aggregates
2. Specific Gravity
3. Water Absorption
4. Bulking of sand
5. Silt Content
Coarse aggregates:-
1. Sieve Analysis or gradation of aggregates
2. Specific Gravity
3. Water Absorption
Cement:-
1. Fineness of cement
16. Water:-
1. pH value
Fresh concrete:-
1. Slump Test
Hardened concrete:-
1. Compressive strength
16
1.Sieve analysis or gradation of aggregates:-
Fine aggregates:-
Sand sample taken 500gm
Fineness Modulus = Sum of Cumulative %age retained on the selected sieve/100
= 16.4+34.8+55.6+90.8+96.8/100
= 294.4/100
= 2.9 (medium size)
Fineness Size = 2.2-2.6
Medium Size = 2.6-2.9
Coarse size = 2.9-3.2
Sieve size Retained
aggregates
%age retained
aggregates
Cumulative % of retained
aggregates
Passing %age
10mm 0 0 0 100
4.75mm 0 0 0 100
1.18mm 82 16.4 16.4 83.6
2.36mm 92 18.4 34.8 65.2
600micron 104 20.8 55.6 44.4
300micron 176 35.2 90.8 9.2
150micron 30 6 96.8 3.2
17. 17
S.No. Sieve Sizes Zone I Zone II Zone III Zone IV
1. 10mm 100 100 100 100
2. 4.75mm 90-100 90-100 90-100 95-100
3. 2.36mm 60-95 75-100 85-100 95-100
4. 1.18mm 30-70 55-90 75-100 90-100
5. 600micron 15-34 35-59 60-79 80-100
6. 300micron 5-20 8-30 12-40 15-50
7. 150microns 0-10 0-10 0-10 0-15
Passing %age of the fine aggregates
18
10mm aggregates:-
Take the sample of aggregates 1kg
19. Passing %age for 20mm aggregates:-
25mm = 100%
20mm = 85-100%
10mm = 0-20%
4.75mm = 0-5%
20
Fineness ofcement:-
Take the sample of cement 100gm and 90 micron sieve
Weight of sample = 100gm
Weight retained = 0.18gm
Passing Sample = 100-0.18
= 99.82gm
Fineness of cement = retained residue of cement/100
= 0.18/100
= 0.0018%
2. Specific Gravity
Specific gravity of an aggregate is defined as the ratio of the mass of a given volume of
sample to the mass of an equal volume of water at the same temperature.
20. Fine aggregates
Take the sample (W1) = 500gm
Weight of water + flask (W2) = 1539gm
Pycnometer + water+ sample (W3) = 1847gm
Calculation:-
Specific gravity = W1/W1-(W3-W2)
= 500/500-(1847-1539)
= 500/500-308
= 500/192
= 2.60
Specific gravity = 2.60
21
Coarse aggregates
10mm
Take the sample (W1) = 1000gm
Weight of water + flask (W2) = 3480gm
Pycnometer + water + sample. (W3) = 3575gm
Calculate the specific gravity
Specific gravity = W1/W1-(W3-W2)
= 1000/ 1000-(3575-3480)
= 1000/1000-95
= 1000-905
= 1.10
Specific gravity = 1.10
20mm
Take the sample (W1) = 1000gm
Weight of water + flask (W2) = 3440gm
Pycnometer + water + sample. (W3) = 3575gm
Calculate the specific gravity
Specific gravity = W1/W1-(W3-W2)
= 1000/ 1000-(3575-3440)
= 1000/1000-135
= 1000/865
21. = 1.15
Specific gravity = 1.15
Cement:-
Take the sample (W1) = 500gm
Weight of water + flask (W2) = 1539gm
Pycnometer + water+ sample (W3) = 1847gm
Calculation:-
Specific gravity = W1/W1-(W3-W2)
= 500/500-(1850-1513)
= 500/500-337
= 500/163
= 3.06
Specific gravity = 3.06
22
3. Water Absorption:- The amount of water absorbed by a material under
specified test conditions. Commonly expressed as a weight percent of the test
specimen.
Fine aggregates
Take aggregates (10mm)(W1) = 500gm.
Put the tray in oven for dry the aggregates for 24hours and weight it (W2) = 450gm
Calculate the water absorption:-
Water absorption = (W1-W2)/W2*100
= (500-480)/480*100
= 20/480*100
= 4.16%
Coarse aggregates
10mm
Take aggregates (10mm) (W1) = 1000gm
Put the tray in oven for dry the aggregates for 24hours and weight it (W2) = 980gm.
Calculation:-
Water absorption = (W1-W2)/W2*100
= (1000-945)/945*100
= 55/945*100
= 5.82%
20mm
22. Take aggregates (20mm)(W1) = 1000gm
Put the tray in oven for dry the aggregates for 24hours and weight it (W2) = 930gm
calculations:-
Water absorption = (W1-W2)/W2*100
= (1000-930)/930*100
= 70/930*100
= 7.52%
23
4.
Oven dry sample of sand 200ml. Add 1% of the water by mass of sand
Readings:-
Sample of sand (h) = 200ml
Height of bulking sand (h1) = 170
Percentage of the bulking = h-h1/h*100
= 200-170/200*100
= 3/200*100
= 0.015*100
= 1.5%
5. Silt Content:-
Put the sand200ml incylinderandadd water+ salt
Place itfor half hour,layerof the saltwill formed
Reading:-
Sample of sand = 200ml
23. Layer of silt content =5ml
24
6. Water:-
pH value
1. Take buffer solution with 4 and 7.
2. Calibrate it with meter rod.
Reading
Mean of values = 6.7+6.8+6.9/3 = 6.8
7. Freshconcrete:-
Slump Test
1. Preparedcementconcrete of ratio1:1.5:3
2. Fill the slumpcone in4 layers,eachlayeristempedby25 blows.
3. Remove the cone immigiatelywithcarefullyinverticaldirection.
4. Checkthe slumpheightwiththe helpof tempingrodorscale.
Readings:-
Height of Slump cone = 300mm
Slump value = 80mm
25. 26
Chapter 4
Mix Design
Introduction
Mix Designof M20 Grade:-
Sample M20
Sum = 1+1.5+3
= 5.5
Water cement ratio = 0.45
No. of cubes = 6
Volume of one cube = 0.15*.015*.015
Volume of 6 cube = 0.15*0.15*0.15*6
= 0.02025cum
Materials:-
Cement = 1/5.5*0.02025*0.035*50
= 6.44kg
Sand =6.44*1.5
= 9.66kg
Aggregates = 6.44*3
= 14.50kg
Water/cement ratio = 0.45
Water = 0.45*6.44
= 2.9kg
Code Provisions:-
IS 456:2000 – For water Cement Ratio
26. IS 10326:2009 – For Design of Concrete
IS 383-1970 – For specifications of the Aggregates
IS 2386:1963 - For testing of aggregates
Conclusion:-
We have come to conclusion about what we have done in our whole project work.
So on this we have leant about what is RMC, why is it required, Necessity of RMC, what
RMC all about
In this we get to know all about the various tests performed in a quality controlled lab on the
materials which are used for making the fresh concrete.
27. In this we learnt about the properties of concrete and how to change the properties according
to the needs.
So far we have prepared a model of batching plant to show how plants works step by steps.
References
