Detail report on RMC quality control tests

1. RMC QUALITY CONTROLS
DATE : 01/01/2018
BY
Prof. R. V. Kolhe
Department Of Civil Engineering
SRES’s Sanjivani College of Engineering,
Kopargaon

2. Contents:
• Introduction
• Case study: ISM RMC Plant, Islampur
• Quality control tests
• Quality checklist

3. Introduction
• General
“ The Concrete which is mixed in a central batching and
mixing plant or in a truck-mixer and supplied in the fresh
condition to the purchaser either at the site or into the
purchasers vehicles.”

4. History
• Started in the Germany in 1903
• In India
• for construction of Bhakra-Nangal, Koyna dams in 1950
• The first commercial plant was erected in Pune, 1991
• Currently, there are 400-500 RMC plants working in India
• produces20-25 million cubic m3 of concrete.

5. Objectives
• Selection of the RMC plant for case study.
• To study the plant specifications, resources, operation and
processes.
• Analyze quality control process and practices over there.
• To collect data of three different sites for which RMC is
supplied.
• Check whether the RMC Plant working to its capacity or
not.
• Give the solution for efficient working of the plant.

6. Case study: ISM RMC Plant, Islampur
• Specifications
Plant Model/Make CP 30 Singh -
Production Capacity 30 m3
Capacity of Cement Silo 110 M.T
Capacity of Fly Ash Silo 42 M.T
Production min. per day 30 m3
Production max. per day 180 m3
Time for batch mixing 30 Seconds
Grade of concrete produced M15 to M35 -
Total plant site area 8093.71 m2
Area for stock piles 2023 m2
Total Production 18000 m3
Total Hours working 925 hrs.

7. Plant details
• Name of Owner: Jaydeep Patil
• Location of RMC Plant: IMS RMC, Islampur,
• Date of Establishment: 26 Jan. 2014
• Timings of working: maximum 12 hrs.
• Human resource: 15
• Financial Aspect: Investment cost = 4 Crores
i. Equipment’s cost = 1Crore
ii.Transit Mixer’s cost =1.5 Crores
iii. Land cost = 1.5 Crores

8. Plant details continued…
• Daily wages:
• Supervisors = Rs. 400
• Operators = Rs. 350
• Transit Drivers = Rs. 200
• Workers = Rs. 200
• Raw material cost:
• Cement = Rs.5000 /M.T Sand = Rs. 1766 / m2
• Aggregates = Rs.777 / m2 Fly ash = Rs. 900 /M.T
• Admixture = Rs. 500 /10 Ltr.

9. Cost of Ready Mix Concrete to Client:
Depends on concrete grade and the distance of delivery
• M15 grade = Rs. 3500 /per m3
• M20 grade = Rs. 4000 /per m3
• M25 grade = Rs. 4500 /per m3
• M30 grade = Rs. 5000 /per m3

10. Raw Material Sources
• Cement
• Type of cement used: OPC 43 grade
• Source: Vasavdatta, Brought from Sedam, Karnataka
• Storage: In Silos by Pneumatic blower pump
• Aggregates
• Source: Own crusher
• Storage: In-Line Silo storage by Loader
• Sand
• Natural sand
• Brought from Koyna river

11. • Fly Ash
• Type: Bel Ash
• Source: JSW Plant, Jaygarh, Ratnagiri, Maharashtra.
• Admixture
• Type: Rheobuild
• Brand/Company: BASF, Pune
• Super Plasticizer
• Water
• Source: Bore well

12. Batching plant: Automatic

13. Mixer
• Mixer is used to mix all the ingredients of the concrete.
Uniform workable concrete is produced by the help of
concrete mixer.
• Specifications
• Aggregate scale: 1250 kg
• Cement scale: 250 kg
• Water scale: 150 kg
• Admixture: 6 kg

14. Transit trucks
• The delivery of RMC to the site is made with the help of
transit mixers. It has a revolving drum with axis inclined to
the horizontal.
• Specifications
• Revolution speed: less than 2 rpm
• Capacity: 7 m3
• Time or Discharge limits: 90 min. or 300 rev.
• Water tank capacity: 300 ltrs.

15. Flow diagram for RMC Plant

16. QUALITY CONTOL TESTS
 Tests on Fine Aggregates (Weekly)
1.Sieve analysis (Conforming to IS 2430)
• This test used for proper gradation of the fine aggregates. The fine aggregates
used should be less than 4.75 mm and it should be silt free.
• Fineness modulus within 2.2 to 2.60
•
2.Specific gravity (Conforming to IS 2430)
• The specific gravity required in calculating the compacting factor in connection
with the workability measurements.
• Average specific gravity within range of 2.6 to 2.58
• Water absorption test (Conforming to IS 2386-Part iii)
• Some of the aggregates are porous and absorptive. Porosity and absorption of
aggregates will affect the water/cement ratio and hence the workability.
• The results should be less than 4 %.

17. Tests on Coarse Aggregates (Weekly)
1.Sieve analysis (Conforming to IS 2430)
• Same as that of the fine aggregates.
• Specific gravity (Conforming to IS 2430)
• Same as that of the fine aggregates.
• Average specific gravity within range of 2.6 to 2.58
2.Bulk density test (Conforming to IS 2386-Part iii)
• This test used to determine how much volume of aggregate in one
cubic meter.
• Water absorption test (Conforming to IS 2386-Part iii)
• The water absorption permitted is 4 %. Further this there is increase
in water to cement ratio and workability affects.

18.  Tests on Fly Ash (Report from supplier)
1.Fineness test
• Fineness % retained on the 45 micron sieve should be 12 %
2.Loss on ignition test
• Maximum 4 %
3.Moisture content (Conforming to IS 2386-Part iii)
• Maximum 2 %
 Tests on Water (as per requirement)
1.PH value
• PH should be in range 7 to 8.
 Quality control tests on Fresh Concrete (per 100 m3 production and as per customer
req.)
1.Slump test (Conforming to IS 1199)
• This test used for measurement of workability of concrete.
• Slump for fresh concrete is within 100 to 120 mm.
• 100 mm for dumping and 120 mm for pumping.

19. • Tests on Coarse Aggregates (Weekly)
• Sieve analysis (Conforming to IS 2430)
• Specific gravity (Conforming to IS 2430)
• Aggregate impact value (Conforming to IS 2386-Part iv)
• Bulk density test (Conforming to IS 2386-Part iii)
• Water absorption test (Conforming to IS 2386-Part iii)
• Flakiness index test
• Elongation index test
• Tests on Water (as per requirement)
• PH value

20. Tests on ready mix concrete
• Quality control tests on Fresh Concrete
(per 100 m3 production and as per customer req.)
• Slump test (Conforming to IS 1199)
• Unit weight (Conforming to IS 1199)
• Quality control tests on Hardened Concrete
(per 100 m3 production and per customer req.)
• Compressive Strength (Conforming to IS 516)
• Density
• Flexure strength

21. QUALITY CONTROL CHECKLIST
• Cement
• Cement silos should be waterproof
• If cement is in bags, then its storage facility and should be
weatherproof, damp-proof, free from dust
• If cement is in bulk, then there should be dust-free flow to
the silo
• If different types of cement stored, then it should be
isolated to prevent contamination
• Sign boards for indicating types of cement

22. • Aggregates
• Separate storage for each size and type
• Sign boards for indicating different size
• Prevent intermixing with dust, mud, soil
• Prevent contamination of different sizes
• Avoid degradation which adversely affects properties
• Water
• Adequate storage
• Protected from contamination
• Temperature controls should be there

23. Thank You…
Have a great day ahead…!