JKLAKSHMI POWER MIX

(READY MIX CONCRETE)

QUALITY
MANUAL

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 JKLAKSHMI POWER MIX
(READY MIX CONCRETE)

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PRE-FACE

The Quality Manual is the “written image of the company-JKLakshmi Power Mix-”
.It describes how we should set up & comply with our own quality policy:
• In house –It is the reference document for internal quality management
• In customer relations —it is testimony to quality assurance level that has been
achieved & that is used to win customer’s confidence.
Our Quality Manual documents the policies, procedures, responsibilities, and
documentation, that must be in place for the JKLakshmi Power mix station to comply with
their regulatory responsibilities.

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Document details

O 18-6-2009 S.R.CHITNIS M.SHEKHAR

VERSION PREPARED ON WRITTEN BY VERIFIED BY

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1. Introduction
General
The purpose of this Quality Manual (QM) is to provide documentation of the quality
processes employed by JK Lakshmi Power Mix Company to insure the quality of our
products.
Quality Policy
“At JK Lakshmi Power Mix, Guaranteeing Smart Constructions and Services means
delivering to the customer the quantity and quality of concrete desired within a mutually
acceptable time frame. The concrete, upon delivery, must have been designed,
proportioned, and mixed to meet the performance criteria specified. “

In order to achieve our policy objectives JK Lakshmi Power Mix

• Understands the importance of delivering our concrete in a professional, courteous
manner;
• Strives to continuously improve our operations;
• Purchases and maintains the best equipment available for the tasks required;
• Appreciates our employees as the “driving force” of our business;
• Maintains clean and well-serviced delivery fleet;
• Recognizes our suppliers as partners and a valuable, integral part of our business;
• Understands the importance of personnel qualifications and certification and the
benefits of providing career enhancement opportunities for our employees;
• Is responsive to the needs of our customers;
• Manufactures and delivers consistent ready mixed concrete
• Delivers concrete safely;
• Takes pride in our business.

JK Lakshmi Power Mix has made a firm commitment to quality. It is our policy to produce
products and services that competitively meet our customer’s quality requirements

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2. Quality Management System (QMS)

General
JK Lakshmi Power Mix has defined and documented our Quality Management System in
this Quality Manual. Our Quality Management System consists of those processes,
resources, policies, materials and activities that influence our product and service quality. It
is important to us that we maintain and continuously improve our QMS.
Documentation Requirements
Documentation of our Quality Management System is not our goal, but instead is a means
of achieving our goal. The purpose of documenting our QMS is to:

Demonstrate to our customers our ability to consistently provide ready mixed
concrete that meets their performance requirements

Provide continuity and uniformity of processes;

Enhance training and provide career enhancement to our employees;

Improve customer satisfaction; and

Establish a measurement system to facilitate continuous improvement through
statistically based concepts, when applicable.
Quality Manual (QM)
Defining and documenting our QMS is a part of our company-wide quality initiative. This
Quality Manual addresses multiple functions, which not only include the design and control
of our company's product, but a number of activities indirectly related to the control of
quality.
Quality activities addressed in this Manual include, but are not limited to:
• Sampling and testing of concrete and concrete materials;
• Identifying the testing and evaluations conducted by JK Lakshmi Power mix and
those services that we outsource, primarily for mixture performance for specification
qualification; plant and field control of concrete production;
• Facilities, plants, and equipment;
• Customer focus;
• Order processing and dispatching procedures;
• Concrete delivery and site control;
.

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3. Management Responsibility
General
The senior management of JK Lakshmi Power Mix has established the significance of
quality in our organization and demonstrated their commitment to our company’s quality
initiative. They are committed to the development and implementation of our QMS and to
the continuous improvement of our quality processes.
The Quality Policy illustrated in this Quality Manual reflects the quality principles important
to our senior management and subsequently to JK Lakshmi Power Mix.
The level of our management commitment to quality is a reflection of our desired level of
product quality. Although our Quality Control Dept.capabilities provide a high level of quality
assurance and control, the overall (quality related) decision-making process addresses
many other important aspects of our business.

Planning
The senior management of JK Lakshmi Power Mix understands the importance of
business, financial, and quality planning. It is equally important to our organization to
implement, monitor, and revise our plans, as needed. We conduct in-depth planning each
fall for the following calendar year. Throughout the year, we review our performance
compared to our goals and modify our expectations as required.

Quality Objectives
Before we fully develop our quality plans, we identify and/or review our quality objectives,
which must be consistent with our Quality Policy. Our quality objectives are identified by the
responsible manager and frequently change as we continuously improve our processes.
Our quality objectives are measurable and the method of measurement is defined.
Examples of our corporate quality objectives may include:

Achieving 90 percent on-time delivery;

Achieving 90 percent customer satisfaction;

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Quality Management System Planning

The senior management of JK Lakshmi Power Mix is responsible for identifying and
subsequently allocating the resources necessary for the on-going implementation and
continuous improvement of our company’s QMS. Although many of our quality initiatives
actually reduce operating costs over time, initial quality expenditures are often budgeted for
the following year.
Product Realization
In order to manufacture and deliver the products and services we provide, we have
identified and continuously monitor the sequence of processes (and sub-processes) that
we employ. We have prepared detailed descriptions of the process steps and/or process
flow charts for designated procedures. The interaction of individual and departmental
processes is periodically reviewed for effectiveness and improvement.
Based on input from sales & operations, the senior management of JK Lakshmi Power Mix
ultimately determines the products that we provide. In general, we provide ready mixed
concrete products for residential, commercial and public sectors.
Work Environment
JK Lakshmi Power Mix ensures that the infrastructure of our work environment including
production facilities provides a safe and healthy environment for our employees. Facilities
are provided with the necessary safety provisions for minimizing the risk for injury but
allows for the smooth transition of information flow within the organization. Information
systems and computer software is kept up-to-date with current technology.
The established systems in place ensure for creating a participative work environment that
encourages communication between various divisions and production facilities. We realize
that this is important to our overall QMS. We will continuously strive to provide a
comfortable, safe, and efficient work environment, operating in harmony with nature and
the communities within which we reside.
Factors that need to be addressed to ensure maintaining a work environment that is
conducive to efficient employee work processes and ensuring optimum product quality are
addressed on a quarterly basis by the management team with appropriate follow up tracked

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4. CUSTOMER FOCUS
General
At JK Lakshmi Power Mix we understand and appreciate the importance of customer
satisfaction. We have many capable competitors in our market area and we know that our
customers must constantly make choices regarding their purchases of ready mixed
concrete.

Customer Satisfaction
Although many of our customer requirements are documented in the project specifications,
many of their needs and inherent requirements are not specifically stated. On-time delivery
is a customer expectation that is usually not specified. Our senior management
continuously strives to identify, understand, and meet all of our customer’s requirements.
We listen to our customers.
All proposals and quotations to current and potential customers contain JK Lakshmi Power
Mix standard figures and language or are pre-approved by the RMC Head Business. Input
from operations and Services personnel are a critical aspect for estimating costs and bid
pricing for major projects. All purchase orders and contracts are reviewed for content prior
to acceptance.
At JK Lakshmi Power Mix, our customer focus is internal as well as external. We train our
employees to understand how their work impacts the work of others throughout our
organization. The customer of a driver is the dispatcher and a customer of the dispatcher is
the driver. Both are dependent upon the other in the performance of their duties. A
customer of both the driver and the dispatcher is the accounting person responsible for
invoicing.

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Customer Connections

At JK Lakshmi Power Mix we are constantly seeking opportunities to connect with our
customers. We prefer that they review plans and specifications at customer’s offices. This
gives our sales personnel the opportunity to have one-on-one dialog with our customer
regarding a project that we are both interested in. It also gives us the opportunity to
promote performance-based specifications, when appropriate.
We, as a company, spend a considerable amount of resources promoting our business to
current and prospective clients. With the capable assistance of our Quality Control Dept.
staff, our sales personnel are able to demonstrate to our customers our technical
understanding and knowledge of our products and can quickly respond to their particular
needs.
Representative promotional activities include:

Maintain a website that documents our company’s history and commitment to the
local community, provide the appropriate contact information and products we
typically produce, provide general information on cement ,ready mixed concrete and
the benefits it provides to sustainability and long life structures.

Presentations to customers of our performance records on previous major or special
projects

Expanding markets and applications of ready mixed concrete, to include a wider use
of concrete by owners, designers, and builders.

Distribution of technical literature brochures and other publications with the company
imprint, as applicable to various job situations.

Suggested standard practices for ordering concrete, which will help, ensure that
concrete of the proper quality level will be provided for typical local uses in
commercial and residential construction.

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5. QUALITY AWARENESS
It is the responsibility of our management personnel to insure that all employees are aware
of, and comply with, the provisions of this Quality Manual. Communication of our QMS
begins with each employee’s initial training and continues throughout their employment with
JK Lakshmi Power Mix.
Subsequent employee awareness consists of:
• Every employee understands our company’s intention to produce, deliver, and
service quality ready mixed concrete;
• We continuously educate and train our employees on their role in maintaining our
Quality Management System.
• The Quality Manual is one method utilized by JK Lakshmi Power Mix to create
customer awareness of our shared standard of quality.

QUALITY CONTROL & QUALITY ASSURANCE

Quality control has been basically limited to the control of specific quality characteristics at
the point of release to the customer. Quality Assurance includes all measures to plan &
control the total production process hence Q.C. has been an instrument for the building
authority to ensure conformity to minimum requirements whereas QA is also an instrument
of the industry to plan & control the production process in a way that the required quality
level is achieved under economical cost for any particular production condition.Q.A system
serve also to demonstrate that JKLakshmi Power Mix comes up to it’s responsibility &
shows concern for quality. The role of customer is verify the suitability of our QA system.

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Quality control of ready-mixed concrete can be divided into three convenient areas:
A) Forward control B) Immediate control, C) Retrospective control.
All three include technical and production aspects and use of external data.

Forward control covers:

(i) Materials storage
• Prevention of contamination
• Reliable transfer and feed systems
(ii) Monitoring of qualities of materials
• Visual checks—acceptance/rejection
• Sampling Testing
• Certification by suppliers
• Information from suppliers
(iii) Modification of mix designs
(iv) Plant maintenance
(v) Transfer and weighing equipment
• Controlled flow
• Calibrated weigh scales
• Separate weighing of cement
• Calibrated admixture dispensers
(vi) Batch plant and transit mixers
• Blade condition
• Maintenance.

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Immediate control
Immediate control is concerned with instant action to control the quality of the concrete
being produced or that of deliveries closely following. It covers the following.
(i) Weighing (correct reading of batch data and accurate weighing)
(ii) Visual observation of concrete during production and delivery or during sampling and
testing of fresh concrete (assessment of uniformity, cohesion, workability; adjustment to
water content)
(iii) Use of equipment at the plant designed to measure moisture content of aggregates,
particularly fine aggregate, or the workability of the concrete
(iv) Making corresponding adjustments at the plant automatically or manually to batched
quantities to allow for observed, measured or reported changes in materials or concrete
qualities.
(v) Inspection at delivery by driver and customer for uniformity and workability; adjustments
to workability within company policy.

Retrospective control

Retrospective control covers

(i) Sampling of concrete; testing; monitoring of results
(ii) Weighbridge checks of laden and unladen vehicle weights
(iii) Stock control of materials
(iv) Diagnosis and correction of faults identified from complaints.

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6. Facilities, Plant(s) and Equipment

General
JK Lakshmi Power Mix is a multi-plant ready mixed concrete producer having head office at
New Delhi. We have Nine(9) stationary Ready Mix Concrete plants . Seven plants are
capable to produce 56 Cu.M. of concrete per hour & two plants are of producing 30 Cu.M.
of concrete per hour . We operate a fleet of over 42 ready mixed concrete transit mixers.

Laboratory Facilities

The JK Lakshmi Power Mix laboratory is located over a more than 1200 square foot area.
The majority of the space in the lab is dedicated to the testing of concrete and component
materials. The laboratory maintains copies (printed and/or electronic) of concrete and
component material guidelines, specifications and regulations including, but not limited to:

Related Indian standards latest versions

Quality assurance/quality control records
The maintenance of these records is the responsibility of the QC in-charge
Our laboratory testing priorities are primarily directed at those tests that are most important
to the acceptance of our concrete by our customer. Having the capabilities of testing fresh
concrete and the strength (and other properties) of hardened concrete, are extremely
important to our concrete operations. Additional laboratory testing includes certain tests for
significant properties of aggregates, recycled rinse/wash water, and other concrete
materials, which have a bearing on our company’s concrete performance. Dry aggregates
are sieved for Particle Size Distribution of aggregates. Motorized sieve shakers are
commonly used. We use soft bristle brush to clean sieves. The aggregates that are not
passing the tests are summarily rejected & not unloaded at yard.
A list of equipment in the Laboratory is provided in Appendix
Tests that cannot be performed in our laboratory are outsourced, as required.

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RECOMMANDED TESTING FRQUENCY

S.No. Test Frequency Remarks

A Stone Aggregates
1 Moisture Daily more if source changes
2 Sieve Analysis Daily more if source changes
3 Bulk density Weekly more if source changes
4 Sp.gravity Weekly more if source changes
5 Impact value Weekly more if source changes
6 Abrasion value Weekly more if source changes
7 Soundness Yearly more if source changes
B Sand
1 Silt content Daily more if source changes
2 Moisture Daily more if source changes
3 Sieve Analysis Daily more if source changes
4 Bulk density Weekly more if source changes
5 Sp.gravity Weekly more if source changes
C Fly Ash
1 Fly Ash % passing 300 Daily more if source changes
micron sieve
D Concrete
1 Slump Each Transit
Mixer
2 Concrete cubes As per IS 456 As per customer’s requirement
3 Yield Daily For each grade of concrete
4 Air-content Daily For each grade of concrete
5 Concrete Temp. Each Transit
Mixer
6 Air temp. Each Transit
Mixer
E Water
1 Clorides Half yearly Accredited lab.
2 Suspended solids Half yearly Accredited lab.
3 Sulphates Half yearly Accredited lab.
4 Organic Half yearly Accredited lab.
5 Inorganic Half yearly Accredited lab.

Note—all above tests must be carried out in a NABL accredited lab. yearly

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Control of Monitoring and Measurement Devices

It is the policy of JK Lakshmi Power Mix to have our concrete plant scales calibrated every
six (6) months. As defined in our Purchase Order for concrete admixtures, we require our
admixture supplier(s) to calibrate admixture dispensers quarterly and provide the
appropriate documentation. The Plant Manager at the Plant maintains Equipment
Calibration Records. If any equipment is found to be out of calibration, the reason is
determined, and the cause corrected immediately.
The hydraulic testing (compression) machine in the laboratory is calibrated annually.
Thermometers, and Air Meters are calibrated in accordance with manufacturer
recommendations. The Quality Control Manager at our laboratory maintains all records of
laboratory equipment certifications.
Calibrations are performed at any time the equipment indicates erratic results, and in any
case at intervals not greater than the aforementioned calibration frequency.

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CALIBRATION & ACCURACY OF WEIGHING EQUIPMENTS

a. Cement, mineral admixtures > Within +-2% of the qty. of the constituent being
measured

b. Aggregate, chemical admixtures & water > Within +- 3% of the qty. of the constituent
being measured

c. Analogue scales shall have scale increments not exceeding 5-kg for cement and
mineral admixtures, 25-kgs for aggregate and 2-kg for water

d. Chemical Admixture dispensers shall have scale increments not exceeding :

Range of scale in kg/l Scale increment in kg/l

-------------------------- ----------------------------

0.1 - 0.5 0.01

0.5 - 1.0 0.02
1.0 - 10.0 0.2
more than 10.0 0.4

e. All weighing and measuring equipment shall be tested and calibrated over its full
working range at the following intervals:-

1) Mechanical/knife edge systems > At least once every two months

2) Electrical/local cell systems > At least once every three months

Adequate and identified facilities shall be provided for the application of the test loads

f. To achieve the required accuracy of calibration, a minimum of 500 kg of stamped

weights are required, except that for low capacity scales an acceptable limit on the total
mass of calibration weights would be 20% of the scale capacity.

g. When calibration of weighing equipment is carried out al personnel involved should be

competent and fully trained, the procedures should be fully documented, and special
attention should be paid to the health and safety aspects of the procedure.

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Equipment Maintenance
JK Lakshmi Power Mix has a structured preventive maintenance program which includes
all production equipment. Equipment is inspected, and repaired if necessary, at
predetermined intervals based on the importance and condition of the equipment.
Preventive Maintenance processes for our concrete plants include, but are not limited to:
Silos for Cementitious Materials

Providing moisture proof storage and physical separation by means or separate
silos.

By determining accumulation of cement in compartment left in “empty” condition.

Checking for accidental “cross-feed” in transfer devices.

Monitoring the high-bin indicators, anti-overfill devices and pressure sensors for
correct operations.

Inspecting the Dust Collection systems in accordance with the manufacturer’s
recommendations.
Aggregates

Providing physical separation of aggregates by type.

Monitoring transfer devices, turn head limit switches, and full-bin signals for correct
operation.
Chemical Admixtures

Confirming that admixture storage containers are properly identified with the
chemicals stored within.

Inspecting agitation devices as required to maintain uniform solution densities

Insuring that admixture dispensers are functioning correctly. Making sure that sight
glasses are clean and are provided with legible graduations.

Periodically checking for tank integrity and for leaking hoses and faulty connections.

The dispenser units at our plants are visible from the batcher station for immediate
detection of any malfunction.

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Batching Equipment

Making sure that weigh batchers; the scale linkages clean; that wind protection is
adequate for cement weigh batchers; there is no binding against the frame or other
obstructions (check when weighing capacity loads); and there is no binding of scale
cables (at entry port to control house).

Insuring that the cement weigh batcher is properly vented and there is no back
pressure on the scale system from pneumatically charging the cement or pozzolan
silos (aerator; or from pneumatic unloading of transportation units).

Monitoring batching records for verification of batching accuracy.

Rotating the sheaves or cable pulleys periodically for uniform wear.

Discussing record maintenance policies relative to time and cross reference to
delivery tickets.

Making provisions for periodically checking the actual admixture discharge into
mixer.
Central Mixer

Visual checks (as part of plant startup) for build-up of hardened concrete and blade
wear weekly.

Mixer uniformity evaluation for slump and coarse aggregate tests biannually.
Transit Mixers

Checking for concrete build-up,

Blade wear,

Hour meter, in working condition,

Accuracy of water gauge or meter, general condition of truck water system (legible
quantity indications, clean gauge, no water leaks), legible mixer rating plate.

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PREVENTIVE MAINTENANCE

S.N. PARTICULARS FREQUENCY

1. BATCHING PLANT & SILO FEEDING SYSTEM

a. Clearing the Central mixture pan and clearing all debris Daily
b. Greasing and oiling of skip, screw conveyors etc. Daily
c. Check the connecting holes cement & fly ash Daily
d. Ensure weighing hopper empty properly Daily
e. Check sand and aggregates are fed in skip without any
leakage Daily
f. Check arms, paddle, mixture blade etc. for wear &
tightness and adjust the gaps Weekly
g. Maintain the bag of filters clean
h. Check clean the knife edges/load cells in weighing
equipment Weekly
i. Maintain all hoppers and doors in clean and efficient
working orders Weekly
j. Check oil level on air line lubricators Weekly
k. Check water traps on air line Weekly
l. Check rams and air lines for leakage Weekly
m. Check piping for leakage Weekly
n. Routine greasing of screw conveyor, baring and gears
etc. Monthly
o. Calibration of wastage water meter and admixture Monthly
dispensers
p. Check electric wiring or heating, loose hanging wire etc. Monthly
2. AGGREGATE BELT CONVEYOR

a. Clearing and clearing the pit near tail drum Daily

b. Alignment of the belt Weekly
c. Greasing and servicing Weekly
3. TRANSIT MIXER

a. Wash out truck mixture drum Daily

b. Removing the set concrete in drum Weekly
c. Checking the blades for wear Monthly
d. Calibration of transit mixture water meter Monthly
4. CONCRETE PUMP

a. Check for leakage of oil , slurry etc. Daily

b. Report any other defect or replacement of spare parts Daily
c. Carryout the service as per guidance of service Engineer Regularly

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REPORT OF PLANT INSPECTION

Plant Inspection Date-----------------
Previous Inspection Date------------

ITEMS INSPECTED CHECK BY COMMENTS OR CORRECTIVE ACTIONS

CEMENTITIOUS MATERIALS SCALES

Calibration
Maintenance tolerance
Visual
Other

AGGREGATE SCALES
Calibration
Maintenance tolerance
Visual inspection
Other
WATER BATCHING DEVICES
Calibration
Batching accuracy
Other

ADMIXTURE DISPENSERS
Calibration
Batching accuracy and leaks
Other _____

CENTRAL MIXER
Visual inspection
Uniformity Tests
Other _______________

CONVEYOR BELTS AND ROLLERS

Visual inspection
Other _______________

CEMENTITIOUS MATERIAL BINS OR SILOS

Visual inspection
Other _______________

Screw conveyors
Visual inspection
Other _______________

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7. Materials Management
General
The quality of our ready mixed concrete is based, to a large extent, on the component
materials used in the manufacture of the concrete. We select component materials as
indicated in the following sections and inventory a number of component materials to be
used in the production of our concrete. Component materials stored at our facilities include:
cement, fly ash, silica fume, concrete admixtures, fine aggregates, coarse aggregates,
fibers, and water.

Materials Handling and Stockpile Procedures

All of the JK Lakshmi Power Mix plants are served by truck. The Plant Manager and yard
personnel at each plant receive extensive training in materials management. All drivers
delivering component materials to our plants receive instructions regarding the yard layout,
traffic flow, speed limit, personal protective gear, and materials discharge or placement.
Aggregate ground storage areas are contained on three (3) sides and labeled by the
material stored within. The fill pipes for overhead cement and cement supplement silos are
clearly labeled for the respective silo.
Aggregates are stockpiled within ground storage bins, transferred by a front end loader to a
hopper, and conveyed to Compartment bins . The aggregate bins are charged (receive
materials) by a stationary conveyor with a turn-head. Each bin is clearly labeled on the bin
and on the control panel, if applicable.
We use the following Table to summarize a Plant’s Material Handling:

MATERIAL HANDLING

MATERIAL DELIVERY TO PLANT TRANSFER SYSTEM STORAGE TO

MIXER
Cement Tanker Truck (Bulker) Silo –Feed by Silo – Screw
pneumatic system Conveyor

Fly ash Tanker Truck (Bulker) Silo – Feed by Silo – Screw

pneumatic system Conveyor
Aggregates Dump Truck Compartment Bin— Aggregate Bins -
stationary conveyor— Conveyor
front end loader
Chemical Truck –barrels Barrels Admixture Tanks
Admixtures - pumped

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Production Environment

The environment that we operate in can have a significant impact on the quality of our
ready mixed concrete. Most of the year, we operate with necessary precautions as per
local climatic conditions.. During extreme conditions, we utilize hot and/or cold weather
concrete practices. The temperatures, which necessitate hot
and cold weather concrete practices may vary based on specification requirements.
Our procedures for hot weather (Indian standard IS 456 or ACI 305) concreting may
include, but are not limited to:

Loader operators are instructed in areas of materials management.

Proper blending of coarse & fine aggregates in respective bins is ensured under
guidance of QC personnel.

Coarse aggregate stockpiles are continuously watered for cooling (aggregate
moisture contents are verified regularly).

Delays in the ordering and delivery of concrete are minimized. All concrete is placed
within 3 hours of the time the concrete was batched.

Random loads have temperatures checked throughout the day.

Various admixtures are used to avoid early setting of the concrete. Determination of
the proper admixture and appropriate dosage rate is determined by the QC dept

Chilled water, ice can be added at the customer’s expense.

Re-tempered concrete is not used. During the placement of the concrete, if the
concrete becomes stiff and requires the addition of excessive water for workability, it
is disposed.

Determination of the proper admixture and appropriate dosage rate is determined by
the Quality Control In- charge or qualified designated delegate.

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Control of Plant Operations

It is important to us that we have adequate procedures in place to monitor our concrete
production on a daily basis.
JK Lakshmi Power Mix specific controls include, but are not limited to:
I. Materials Receiving
a. Materials are checked for conformance with the bills of loading or invoice
b. Stockpiles are visually inspected for contaminants, deleterious materials (clay coal and
lignite; off-color sand), wood sticks, and excessive under/oversize coarse aggregate.
c. Blending & reclaiming of aggregates on daily basis by front end loaders at storage bins
under the supervision o Quality Control officer

Acceptance criteria for raw materials

MATERIAL TEST Acceptance Remarks

Criteria
Stone Impact value < 25 & IS 2386 6 samples from
Aggregates Sieve analysis IS 383 each truck at
Flakiness Index < 15 & IS 383 different locations
but not at surface
Sand Silt < 3 % & IS 383 6 samples from
Sieve analysis IS 383 each truck at
Clay IS 383 different locations
Organic IS 383 but not at surface
impurities
Admixture Relative Density IS 9103
Ash content IS 9103
Solids IS 9103
Chloride content IS 9103
Setting time To satisfy mix Trials for two diff.
Strength concrete design Grades must be
requirements conducted

Entries of all trucks are made in the register but materials, which do not conform to
acceptance criteria, are rejected & are not unloaded but entry is marked by Red ink in the
register. Each rejection is brought to the notice of Production Engineer. Three rejections
in a week or four rejections in a month are brought to the notice of Material Purchasing
authority for taking correcting action.

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II. Materials Storage and Handling

• Cement and Pozzolan Silos
The respective fill pipes are properly labeled and bulk loader (tanker truck)
unloading is monitored.

Material Pipe color Color of letter for legend

Cement Yellow Black
Fly ash Purple Yellow

Positive identification of the content of a piping system shall be by lettered legend

giving the name of the contents in full or abbreviated form.

Arrows shall be used to indicate direction of flow.

Legends shall be applied close to valves and adjacent to changes in direction,
branches, and where pipes pass through walls or floors, and at frequent intervals
on straight pipe runs.

Identification may be accomplished by stenciling, the use of tape, or marker

• Aggregates
a. The respective bins are properly labeled

SIZE(MM) BASE Color of letter for legend BORDER

600 X 1500 Yellow Black Red

b. Proper storage (stockpile) procedures are used to prevent harmful segregation and
degradation and to provide for uniform moisture as used.
c. Coarse aggregate stockpiles are sprinkled for cooling during hot weather
concreting.
d. Conveying processes are observed to minimize or eliminate spillage or overflow
into adjoining compartments.

• Chemical Admixtures
a. Admixtures are protected from contamination and dilution (rain water seepage;
splash water from truck wash down; etc.).
b. Admixture deliveries are monitored & follow FIFO (first in first out) system.

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III. Weighing and Batching
• Measuring Accuracy
a) A daily scale check is performed, including verifying zero and tare on the scales.
b) Measuring devices are monitored for compliance with the applicable tolerances.

• Batching Accuracy
a. Batching accuracy is monitored, specifically our automated units, at designated
intervals as shown
b. Batching stations are provided with current mix information and invalid or obsolete
information is promptly removed.

• Batching Procedures
a. The sequence of charging materials into the mixer is standardized.
b. Delivery tickets indicate all of the information
c. Our company policy on the disposition of returned concrete is observed.
d. Our plant personnel are provided with guidelines on handling non-conforming
batches of concrete.

• Mixer and mixer controls

a. Central Mixer
The concrete mixing time is monitored to insure that the optimum mixing
time is observed.

b. Transit Mixers & concrete pumps

All ready mixed truck drivers are aware of the required amount of the
standard mixing and agitating speeds.

Every transit mixture is clear off the concrete debris at the end of the day. It is the
responsibility of Transit Mixture Operator to keep it neat, clear and clear from
debris.

Concrete Pump Operator should check any leakage of oil, slurry etc. and
immediately take preventive action to plug the leakage.

Every Sunday is treated as preventive maintenance day and it is the responsibility
of Production In charge to keep the Plant and Machinery in healthy position.

History sheets of all equipment are up dated weekly

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8.Concrete Testing
General
The reasons for our concrete testing include the evaluation of component materials; concrete
mixture proportioning; and the quality control of our ready mixed concrete production. This
Section describes our Quality Control organization and the procedures for sampling and testing
our concrete. Ready mixed concrete is a simple, flexible, durable, and economical product with a
multitude of applications. In order for our concrete to perform as specified, the concrete must
possess certain properties, which are necessary for the application intended. To confirm that the
desired properties or performance criteria are (or will be) achieved, it is necessary for us to test
our concrete in both a plastic and harden state.

Sampling and Testing of Freshly Mixed Concrete

Acceptance testing of our ready mixed concrete requires sampling in accordance with IS 1199 or
IS 456,. We consider it critical that sampling for acceptance testing be accomplished by the
precise techniques specified in order for the sample to be representative of the concrete being
tested.

According to ASTM C 172, the sample(s) from stationary mixers and revolving drum truck mixers
shall be taken during discharge from the middle portion of the batch. Samples for truck mixed
concrete are generally taken at the job and samples from central mixed concrete may be taken
at the plant and/or at the job site.

The following standardized procedures are used for sampling and testing of the company’s
quality assurance purposes.

TEST REF. INDIAN STANDARD

Concrete Cube IS 516
Yield IS 1199
Air Content IS 1199
Slump IS 1199
Sampling Fresh Concrete IS 1199

We require the use of a “check” test for all nonconforming test results. Once the concrete is
confirmed as nonconforming, the batch plant and Quality Control Department are notified
immediately.

Check test are performed to verify the adequacy of yield adjustments. The testing frequency is
dependent upon the variability of density or unit weights. A history of yield information is
maintained for each monitored mix design.

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Concrete Tests Frequency

The accuracy and reliability of our (quality control) tests results, in representing the
concrete tested, is largely dependent upon the frequency of tests we perform.

PRODUCTION
SAMPLE CUBE TAKEN (No)
QUANTITY (CuM)
Up to 5 1 6
Up to 15 2 6
Up to 30 3 12
Up to 50 4 15
Up to 100 5 18
Up to 150 6 21
Up to 200 7 24
Up to 250 8 27
Up to 300 9 30
Up to 350 10 33
Up to 400 11 36

A random sampling procedure shall be adopted to ensure that the sampling shall be spread
over the entire period of concreting & cover all mixing units.

Acceptance criteria for Characteristic Comp. Strength Requirement

Specified Mean of the group of Individual test results

grade Non-overlapping consecutive N / mm2
test results N / mm2
M 10 ≥13 ≥7
M 15 ≥18 ≥12
M 20 ≥24 ≥16
M 25 ≥29 ≥21
M 30 ≥34 ≥26
M 35 ≥39 ≥31
M 40 ≥45 ≥36
M 45 ≥50 ≥41
M 50 ≥55 ≥46

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9. Concrete Delivery and Site Control

General
Our concrete delivery process begins when the ready mixed concrete truck leaves our yard and
ends when the truck returns to the plant or other designated facility. We require that all of our
ready mixed transit mixers be equipped with rock or chute guards; drums rotate at agitation
speed during travel; transit mixers may not stop for food or breaks on the way to the jobsite and
must seek permission from Production Engineer to stop on the way back; and that any concrete
spillage be reported immediately to dispatch.

Jobsite Monitoring and Control

We are well aware of the importance of our truck drivers as representatives of JK Lakshmi
Power Mix. From a customer focus standpoint, many of our customers will never meet anyone
else from our organization other than our driver(s). From a quality standpoint our drivers are
often our primary jobsite liaison.
We place considerable emphasis on training our drivers in jobsite awareness, including but
not limited to:

Unusual concrete appearance (under/over sanded mix, elongated aggregates, etc.)

Observations of the sampling (middle of load) and testing procedures of the Owner’s
testing agency;

Care and handling of concrete cubes;

Water added on the jobsite (requested and signed for by the customer);

Other materials added by the customer;

The slump as used;

Adverse weather conditions; and

Location of concrete placement (on unstable base, on poly, on clay, etc.).

Certain jobsite conditions necessitate prompt notification of dispatch, batch plant, and/or Quality
Control personnel. Notification of jobsite irregularities are communicated from the driver to Plant
Engineer and Plant Engineer is responsible for notifying the proper individuals or Department.
On major and unique projects our Quality Control personnel often visit the site to observe
operations and monitor concrete sampling and testing. Specific areas observed include water
demand, rate of slump loss, workability, bleeding rate, finishing characteristics, and setting time
of concrete.

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Sampling of concrete—Slump & cube casting

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Occasionally a specification will require the manual addition of admixture on the jobsite, in which
case we will store a tank of admixture on the jobsite. A Quality Control representative of JK
Lakshmi Power Mix is the only individual authorized to make jobsite admixture additions to our
concrete, unless other delegates are authorized by the Quality Control Manager. JK Lakshmi
Power Mix does not provide any warranty for concrete when the customer adds water,
fibers or other additives.prior to pump placements of ready mixed concrete. The Site
Supervisor ensure Checklist for Pumping Ready Mixed Concrete is filled & completed.
Normally when we begin concrete pumping operations for placements on a new project, we
have a Quality Control representative on site to confirm the pump ability of the mix.
Our recommended lubricating mix for Concrete Pumps is as under.-
Length Quantity of lubricating mix Cement Sand
(Liters) (Kg) ( Kg)
50 M 200 200 100
100 M 300 300 150

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Safety

Cement is in alkaline nature hence prolonged contact with wet concrete may cause minor skin
irritations, or, in extreme cases, even burns. The abrasive effect of the sand in the mix can
aggravate the situation, so it is necessary to keep those parts of the body covered that may
come into contact with wet concrete.
i. Wear long sleeved shirt
ii. Protect hands at all times with waterproof hand gloves.
iii. Wear gumboots /shoes. Remove any concrete that get into the boots. Wash them
thoroughly until clean.
iv. Wash the concrete off the skin immediately. If irritation persists after washing, medical
attention should be sought..
v. If concrete enters the eye, immediately wash it out thoroughly with clean water & seek
medical treatment without delay.

Jobsite safety requirements may include the use of hard helmets, safety glasses, earplugs,
safety vest, and/or uniforms. We emphasize to our employees the importance of complying with
jobsite requirements for personal protective gear and observing jobsite speed limits.
Jobsite environmental concerns are adding increased responsibilities to us as a ready mixed
concrete producer. Our drivers receive training regarding jobsite truck (chute) rinse procedures
and rinse water restrictions that may apply to certain projects. Each of our plants has established
procedures for the utilization of excess (returned) concrete.

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ENVIRONMENTAL PRACTICES

In comparison with other primary manufacturing facilities or activities, ready mixed concrete
plant operations do not generally pose a significant threat to the environment. This does not
preclude the importance of environmental awareness by our plant manager or employees.
It is important to recognize at all times that ready mixed concrete plant activities and operations,
without proper controls and mitigation measures, can result in adverse affects that may impact,
either singularly or in combination. Some facilities, depending on location and volumes of ready
mixed concretes produced, may require greater control and management of onsite environment
issues. Prevailing wind conditions or different land uses adjacent to the plant site may result in
more rigorous or modified dust suppression activities.

COMMUNITY AFFAIRS AND PUBLIC CONSULTATION

An important goal of the JKLakshmi Power Mix is to be a responsible corporate citizen and a good
neighbour. It is essential that we should make every reasonable effort to improve company relations with
the surrounding community. This may include maintaining a positive Our image of the plant and
equipment as well as participating in local community affairs. can significantly impact the perception of
their neighbours and others in their community by participating in community affairs. This involvement
can take several forms (e.g., holding open houses for neighbours and community leaders, or the
contribution of goods or services for worthwhile community projects).

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TRAFFIC MANAGEMENT

Good community relations require reasonable access controls and truck traffic management.
At JKLakshmi Power Stations we undertake & encourage following measures
 Post appropriate truck speed limits and always enforce them;
 Keep trucks (raw materials & transit mixers) away from nearby homes whenever possible
 Follow the established truck routes in our community
 Due regard of drivers to traffic regulations is insisted upon at all times and they must
show courtesy to other road users.
 All vehicles traveling outside the site are kept clean and exhibit a well cared for
appearance.
 Regular maintenance ensures that vehicles work efficiently so that noise levels and
exhaust emissions are kept within approved limits.
 Any oil or fuel leaks are corrected immediately and all spillage removed. Care is taken to
prevent vehicles carrying mud, dust or other material beyond the site entrance.
 Waste concrete deposits are also removed from vehicles to avoid spillage on the public
highway:

EXTERNAL APPEARANCE
At JKLakshmi Power Stations, all landscaped, planted and grassed areas are maintained on a
regular basis. Entrance gates and site boundary fences are kept in good condition and where
appropriate, the planting of trees and shrubs is given continuing attention to enhance the overall
appearance.

Plant, office buildings and staff facilities

At JKLakshmi Power Mix stations, plant and machinery are maintained regularly and repaired as
necessary. All paved areas and roads are cleaned and tidied on a regular basis. Office buildings
are cleaned and cared for internally and have adequate toilet facilities for staff and visitors.
Appropriate records such as site layout plans, plant
drawings, planning permissions, site licenses and safety procedures are retained at the site
office.

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Definitions
Accelerator - Chemical substance added to a concrete mix that reduces the set time by
increasing the rate of hydration.

Aggregate - Concrete is a mixture of water, Portland cement, and aggregates (sand and/or
stone). Sand is considered a fine aggregate, while any stones are coarse aggregates

Aggregate aspect ratio – The ratio of length to width of individual pieces of coarse aggregate.
Aggregates characterized, as “harsher” tend to have higher aspect ratios

Air Entrained - microscopic air bubbles intentionally incorporated in concrete during mixing to
increase durability

.Air-migration – The undesirable condition in which entrapped air in fresh concrete migrates to
the top surface causing a bubbling or boiling appearance. This is an indication of unstable air
and a low viscosity mortar. Air popping is another term used for this occurrence.

Bleed water – The water that appears to rise to the surface of concrete subsequent to
placement. ACI defines bleeding as “the autogenous flow of mixing water within, or its
emergence from, newly placed concrete or mortar; caused by settlement of solid materials within
the (concrete) mass.”

Blocking – The condition in which coarse aggregate particles combine to form elements large
enough to obstruct flow of the fresh concrete between reinforcing steel or other obstructions in
the concrete formwork. This property is of increased importance in SCC because of the absence
of vibration energy to dislodge these blockages.

Cohesiveness – The tendency of concrete to stick together, resulting in resistance to

segregation, aggregate settlement, and bleeding.

Curing - The maintenance of the proper moisture and temperature of concrete in its early stages
so that desired properties may develop.

Fines – All dry materials in concrete passing the 2.36 mm (No. 8) sieve.

Finishability – The ease with which concrete can be finished to achieve the desired surface
flatness and smoothness on that portion of an element that must be finished. Finishability does
not refer to formed surface finish quality.

Flowability – A property of fresh concrete indicating the ease of flowing without manual or
mechanical effort. This is a component of filling ability, but a concrete can have high flowability
without high filling ability, if the passing ability is poor.

Grout - A mixture of cement water and sand. No coarse aggregates (stone) is added to grout

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Moisture control of aggregates – A critical factor in production of concrete, in that variations in
moisture content accounted for in normal concrete by plant or site adjustment can cause
concrete to vary in filling ability and segregation resistance by more than acceptable amounts.
Thus tests or measurements for moisture control are required to be done more precisely and
more frequently while producing concrete
.
Mortar fraction – The volume percentage of all materials in the mixture (binder,
aggregate,water, air) that pass the 2.36 mm (No. 8) sieve.

Paste – The volume percentage of the concrete mix comprising binder (cement +
supplementary cementitious materials + unreactive powders), water, admixtures and air.

Placeability – The ability to place concrete in the time span required such that the material
remains homogenous while exhibiting all the required fresh concrete properties.
A general term, encompassing elements of filling and passing ability, as well as time-dependent
change.

Plastic viscosity – The rheologist’s term for measurement of a material’s resistance to increase
in its rate of flow with increasing application of force. In a plot of the force versus the flow
rate,the higher the slope, the higher is the plastic viscosity. SCC mixes tend to have moderate to
high plastic viscosity.

Powder additions – Finely divided inorganic material used in SCC in order to improve certain
properties or to achieve special properties. There are two types of inorganic powder additions: 1)
nearly inert powder additions such as ground limestone or aggregate fines, and 2) pozzolanic or
latent hydraulic powder additions such as fly ash, metakaolin, silica fume or blast furnace slag.

Powder-type SCC – SCC mixes that rely on high amounts of powders in the mix to meet SCC
performance requirements. The higher powder contents increase cohesiveness and segregation
resistance at high filling abilities.

Preset time – The time required to reach a degree of stiffening of concrete equal to a strength of
3.45 MPa (500 psi) as measured by penetration resistance test or other means. Also referred to
as initial set time.

Production control: quality control during production together with operation of preventive
measures by production staff.

Pumpability – The ability of an concrete mix to be pumped without significant degradation of its
fresh concrete properties.

Quality Assurance: the operation of systems by which the client can be assured that control is
being applied over all aspects of the complete process from enquiry to delivery to ensure
compliance of the product with the specification agreed with the client. This involves the whole
management team and their staffs together with independent inspection.

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Quality control: the operation of procedures to maintain product quality at the selected level.
This involves decisions and actions by technical, production and general management.

Quality monitoring: measurement of quality and advising of necessary changes to maintain

quality at the selected level—operated by technical and production staff on raw materials and
products.

Rheology – The science of the deformation and flow of materials. Certain of the critical
properties of fresh concrete can best be understood through the principles of rheology.

Rheometer – A device used to test the deformation and flow of materials. In studying SCC,the
critical parameters measured are yield stress and plastic viscosity.

Saturated surface dry (SSD )—The percentage of water absorbed by an aggregate when
o o
immersed at 27 C for 24 hours, the aggregate being previously dried in an oven at 105 to 110
C to constant weight.

Self-consolidating concrete (SCC) – Also known as self-compacting concrete, a highly

workable concrete that can flow through densely reinforced or complex structural elements
under its own weight and adequately fill voids without segregation or excessive bleeding, and
without the need for vibration.

Settlement – A form of segregation in which the aggregates in SCC tend to sink to the bottom of
the form resulting in a non-homogenous concrete.

Settlement resistance – The ability of a concrete mixture to resist settlement.

Slump flow test – A test method using the standard Abram’s slump cone (upright or inverted)
on a flat surface to measure the unconfined flow and stability of SCC.

Slump flow T500 (T20) – Measurement of the time it takes for the slump flow patty to reach a
500 mm (20 in.) diameter circle drawn on the slump flow plate, after starting to raise the slump
cone. Most SCC will have a T500 (T20) of 2-5 seconds. The longer the time (at the same slump
flow), generally the greater the passing ability.

Stability – The ability of SCC to remain homogenous during mixing, transportation, handling,
placement, finishing and curing.

Static stability – The characteristic of fresh SCC to maintain a uniform distribution of all solid
particles and air voids once all placement operations are complete.

Stickiness – The property of concrete that relates to its propensity to adhere to finishing tools
and other surfaces with which it comes in contact.

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Stone powder addition – Finely crushed limestone, dolomite, or granite with particle sizes
passing the 150 µm (No. 100) sieve that may be used to increase the amount of powder in SCC
mixes.

Thixotropic behavior – The property of a material that it exhibits a low viscosity while being
mechanically agitated and for a while after, but stiffens after a period of rest. This is different
from the normal Bingham plastic behavior of concrete, in which it appears to exhibit lower
viscosity while moving than at rest, in that a change over time while at rest is required for a
material to be thixotropic.

U-Box test – A test involving a U-shaped filling apparatus composed of two separate chambers
used to measure the filling and passing ability of SCC. The concrete is held in one side of the U,
then a gate is opened allowing the SCC to pass through a reinforcing bar screen to the other
side. The characteristics of SCC are assessed by comparing the height of the mixture on one
side of the U (h1) to the height on the opposite side of the U (h2).

V-funnel – A device for testing the flowability of SCC by determining the time for a measured
amount of concrete to flow through a funnel opening of a specific size. Due to possible
aggregate blocking in the throat of the funnel the resulting time can be a complex measure of
both flowability and passing ability, and may be difficult to interpret.

Viscosity – A rheological term defined as the magnitude of the change in the applied stress
required for changing the unit flow velocity of a material – in other words, the slope of the stress-
shear rate curve. In simpler terms viscosity is how “thick” a fluid behaves. Simple fluids like
water or oil, which have no yield stress, appear to have the same “thickness” regardless of how
fast they are moving, and are called “Newtonian.” Concrete, which follows so-called Bingham
behavior, will have different apparent viscosities, with the lowest apparent viscosity at highest
speed of shear.

Visual Stability Index (VSI) – A rating of the visual appearance of the slump flow patty to
evaluate several parameters as an indication of the stability of the SCC mix. The VSI ranges
from 0 for excellent; 1 acceptable; 2 needs improvement; to 3 unacceptable. There are specific
guidelines for each rating.

Viscosity modifying agent (VMA) – An admixture that, when added to concrete, increases the
plastic viscosity and improves the stability of the mixture at a constant fluidity.

Water to cementitious ratio (w/cm) – The ratio of the weight of free water to the weight of all
cement and reactive powders such as slag, fly ash, silica fume, and metakaolin.

Water to powder ratio – The ratio of the weight of free water to the weight of all solids
comprising the paste (material passing the 150 µm (No. 100) sieve) in a concrete or mortar mix.

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Water sensitivity – The amount of free water variation within the mixture that causes the
characteristics of an SCC mixture (primarily its stability) to change from an acceptable range to
an unacceptable range.

Workability – That property of freshly mixed concrete or mortar that determines the ease with
which it can be mixed, placed, consolidated, and finished. It is a complex combination of aspects
of fluidity, cohesiveness, compactability, and stickiness, quantified in tests to determine filling
ability, passing ability, and stability.

Yield stress – One of the rheological parameters of fresh concrete, fresh mortar, and fresh
paste. It is the minimum stress required to make the concrete flow. SCC requires a low-yield
stress. Inversely related to slump or slump flow.

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MARKETING
Brand-a distinctive product offering created by the use of a name, symbol, design, packaging,
or some combinations of these intended to differentiate it from competitors

Brand Equity—The goodwill associated with a brand name which adds tangible value to a
company through the resulting higher profits & sales

Brand values—The core values & characteristics of a brand

Call frequency—The frequency with which a salesperson calls on a customer

Customer behavior—The reasons why customers buy, their choice criteria, when, how & where
they buy

Credit Terms-The basis (usually of number of days delay in payment ) on which goods are
released to the customer before payment is received.

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