Project Report

‘GODREJ READY MIX

CONCRETE PLANT i3 ’
 For the fulfillment of the syllabus of the subject
“Industry Internship”
Of the final year of B. Tech Civil & Environmental
Engineering as per V.J.T.I. Mumbai

Project report on:

“READY MIX CONCRETE”

Submitted by:

Vedant Ganesh Suryawanshi

Of

Final year B.Tech in

“Civil & Environmental Engineering”
(2020-2024)

PROJECT GUIDE:

Dr. V B Varekar Sir

(B.Tech ,M. Tech , PhD in Civil & Environmental
Engineering)
(IIT Bombay)

DEPT. of Civil & Environmental Engineering ,

V.J.T.I. Mumbai.
 Certificate
This is to certify that this project work of:

“READY MIX CONCRETE”

Submitted by Vedant Ganesh Suryawanshi
Roll no:- 201010064

Student of final year of B.Tech in Civil & Environmental

Engineering in the academic year 2020-2024, V.J.T.I.
Mumbai.
re
This project work has been prepared under my guidance:

PROJECT GUIDE
Mr. V. B. Varekar Sir

H.O.D. Dean Academics

Dr. A S Wayal Sir Dr. K K Sangle Sir
 Acknowledgement
We hereby express our intense sense of gratitude to our
respected and beloved Mr. V. B Varekar Sir (Civil &
Environmental Engineering ) Without whom we could not be
able to present this project with such great confidence and
determination. He has always been a great force of inspiration
for all the team.

We are also thankful to all our lecturers in

construction technology department who guided us in
completion of this project.

We are also obliged to our principal Dr. K K

Sangle Sir and our head of department Dr. A S Wayal Sir and
to all the staff members of construction technology department
for their equal encouragement during the completion of this
project.

We also thank respected Mr. Nishant

Chandethakkar (Chief Plant Manager) ACC Ready Mix Plant
Mumbai . And all his associates who with such a gratitude
explained us about all the details of the plant.
INDEX
1) Introduction

2) History

3) Understanding Concrete Manufacturing

4) Scope of Ready Mix Concrete

5) Material Required for R. M. C.

6) Equipment Required in R. M. C.

7) Mixing Process

8) Test Carried on R. M. C.

9) Varieties of Concrete

10) Sustainability in Concrete Technology - RMC

11) Challenges in Concrete Manufacturing Industrty

12) Advancement in Concrete Manufacturing Industry

13) Merits And Demerits of R. M. C.

14) Conclusion

15) Project Report

 PROJECT REPORT

AT A GLANCE

Name of Firm : Godrej Construction

Address : Godrej

Nature of Firm : Partnership

Nature of Work : Ready Mix Concrete

% Profit in 1st Year : 13.49 %

B. E. P. in years : 0.48 years

 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.

However, in the case of the truck-mixed concrete, the batched

materials (sand, gravel and cement) are carried and water is
added just at the time of mixing. In this case the cement remains
in contact with the wet or moist material and this phase cannot
exceed the permissible period, which is normally 90 minutes.

The use of the RMC is facilitated through a truck-mounted

'boom placer' that can pump the product for ready use at multi-
storied construction sites. A boom placer can pump the concrete
up 80 meters.

RMC is preferred to on-site concrete mixing because of the

precision of the mixture and reduced worksite confusion. It
facilitates speedy construction through programmed delivery at
site and mechanized operation with consequent
economy. It also decreases labour, site supervising cost and
project time, resulting in savings. Proper control and economy
in use of raw material results in saving of natural resources. It
assures consistent quality through accurate computerized control
of aggregates and water as per mix designs. It minimizes cement
wastage due to bulk handling and there is no dust problem and
therefore, pollution-free.

Ready mix concrete is usually ordered in units of cubic yards or

meters. It must remain in motion until it is ready to be poured,
or the cement may begin to solidify. The ready mix concrete is
generally released from the hopper in a relatively steady stream
through a trough system. Workers use shovels and hoes to push
the concrete into place. Some projects may require more than
one production run of ready mix concrete, so more trucks may
arrive as needed or additional batches may be produced offsite
and delivered.

However there are some disadvantages of RMC to, like double

handling, which results in additional cost and losses in weight,
requirement of godowns 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. The leading ready-mix concrete supplier
worldwide is the Mexican concrete and cement company
Cemex, and their main competitor is France-based Lafarge.

The Ready mix concrete business in India is in its infancy.

Where as in developed countries, nearly 70 per cent of cement
consumption is in the form of ready mix concrete and 25 per
cent in the form of recast, in India, ready mix concrete accounts
for less than 5 per cent and as much as 82 per cent of cement
consumption is in the form of site-mixed concrete. While 70%
of cement produced in a developed country like Japan is used by
Ready Mix concrete business there, here in India, Ready Mix
concrete business uses around 2% of total cement production.

There are several reasons for this. In early 70s both pricing and
distribution of cement was controlled due to shortage of supply.
Ready mix concrete technology could not be implemented as
investors felt that Ready mix concrete plant will starve due to
non-availability of cement. The levy of additional taxes & duties
on RMC, entry tax, excise duty also contributed to the slow
development of the concept.

The growth of RMC is predominantly driven by demand from

the metro cities. In cities like Mumbai,
the mandatory use of RMC is in construction of
flyovers provided the requisite impetus to growth, according to
an ICRA analysis. RMC is particularly useful when the building
activity is located in congested sites where little space is
available for siting the mixer and for stock piling of aggregates.
The use of RMC is also advantageous when only small
quantities of concrete are required or when concrete is to be
placed only at intervals.
Even as the concept of ready-mix concrete (RMC) is still
catching up in the country, cement majors are keenly focusing
on entering the new area in a big way. Anticipating huge
potential for the product, cement majors, including Associated
Cement Companies, Grasim, L&T, India Cements, Priyadarshini
Cements, Chettinad Cement and Madras Cements, are foraying
into the RMC business and the share of RMC is expected to go
up from present levels of around 5 per cent of the total cement
production to the global average of 70 per cent, according to
industry players.

The teething troubles has been overcome by the RMC Industry

and at present there are over 37 RMC plants delivering over one
lakh cubic meters of mixed concrete every month. RMC plants
are working in Delhi area also. Envisaging higher demand, the
16.4-million ton cement major, ACC is planning to beef up its
existing RMC infrastructure of 11 units with two new RMC
units - one at Noida and the other in Mumbai, during the current
year. During the last fiscal, Madras Cements set up two RMC
plants near Chennai, with a capacity of approximately 9 lakh
cubic metres, while Chettinad Cements installed an RMC
facility near Coimbatore. Grasim's RMC business accounted for
a turnover of Rs 116 crore during 2003-04, against a turnover of
Rs 59.8 crore during the previous year.

For growth of the industry, government bodies, private builders,

architects/engineers, contractors, and individuals required to be
made fully aware about the advantages of using ready mix
concrete, government bodies/consultants needs to include ready
mix concrete as mandatory in their specification for execution,
government specifications for CPWD and PWD jobs should
include Ready mix concrete as a mandatory item. Apart form
this tax breaks are required for the growth of RMC and
developers/contractors needs to be discouraged from piling up
materials like metal, sand etc. on roads/foot paths.
 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 plant arrived in 1950’s and use was restricted to

only major construction projects such as, Bhakra dam was the
first projects were RMC was used. Later on RMC was used for
other large projects such as construction of long span bridges,
industrial complexes etc. The first RMC plant was set up in
Pune in 1993.
 UNDERSTANDING
MANUFACTURING OF
READYMIX CONCRETE
Concrete Manufacturing Process
1. Raw Material Preparation: The raw materials (cement, aggregates)
are gathered, measured, and prepared for the mixing process.

2. Mixing: The measured quantities of cement, aggregates, water, and

admixtures are combined in precise proportions. The mixing process
ensures a homogenous distribution of materials.

3. Transportation: The mixed concrete is transported to the

construction site, typically using concrete mixer trucks equipped with
rotating drums to prevent segregation.

4. Pouring and Placement: Upon reaching the site, concrete is poured

into molds or formworks according to the construction design. It's
then leveled and compacted to remove air voids and achieve the
desired shape.

5. Curing: After placement, the concrete needs time to set and gain
strength. Curing involves maintaining adequate moisture and
temperature conditions for a specified period to allow proper
hydration of cement.

6. Finishing: Surface treatments like floating, troweling, or polishing

are applied to achieve the desired texture or appearance.

7. Protection and Maintenance: Once the concrete has hardened, it

requires protection from environmental factors and regular
maintenance to ensure its longevity.

Factors Influencing Manufacturing

 Proportion of Ingredients: The ratio of cement, aggregates, water,
and admixtures significantly affects the concrete's strength,
workability, and durability.
  Mixing and Handling: Proper mixing and handling techniques
ensure uniform distribution and quality of the concrete.

 Environmental Conditions: Temperature, humidity, and weather

conditions during curing impact the concrete's curing process and
final properties.

 Quality Control: Consistent quality checks and adherence to

standards throughout the manufacturing process are crucial for
producing durable and high-quality concrete.

Understanding concrete manufacturing involves a nuanced comprehension

of these components, processes, and influencing factors to produce concrete
of desired strength, durability, and performance in various construction
applications.

SCOPE OF
READY MIX CONCRETE
Long, Long years ago, their where simple houses but in 21 st
century we can see houses constructed in R.C.C. Therefore
concrete got more importance then 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 “READY MIX
CONCRETE”.

By using R.M.C we can save the 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.

MATERIALS
REQUIRED FOR R. M. C.
Admixture: A substance added to the basic concrete mixture to
alter one or more properties of the concrete; ie fibrous materials
for reinforcing, water repellent treatments, and coloring
compounds.
 Air-entraining admixtures (mainly used in concrete
exposed to freezing and thawing cycles)
 Water-reducing admixtures, plasticizers (reduce the dosage
of water while maintaining the workability)
 Retarding admixtures (mainly used in hot weather to retard
the reaction of hydration)
 Accelerating admixtures (mainly used in cold weather to
accelerate the reaction of hydration)
 Superplasticizer or high range water-reducer (significantly
reduce the dosage of water while maintaining the
workability)
 Miscellaneous admixtures such as corrosion inhibiting,
shrinkage reducing, coloring, pumping etc.

Aggregate: Inert particles (i.e. gravel, sand, and stone) added to

cement and water to form concrete.

Cement: Dry powder that reacts chemically with water to bind

the particles of aggregate, forming concrete. Portland cement is
typically used in concrete production.

Fly ash: Fly ash is a by-product from coal-fired electricity

generating power plants. The coal used in these power plants is
mainly composed of combustible elements such as carbon,
hydrogen and oxygen (nitrogen and sulfur being minor
elements), and non-combustible impurities (10 to 40%) usually
present in the form of clay, shale, quartz, feldspar and limestone.
As the coal travels through the high-temperature zone in the
furnace, the combustible elements of the coal are burnt off,
whereas the mineral impurities of the coal fuse and chemically
recombine to produce various crystalline phases of the molten
ash. The molten ash is entrained in the flue gas and cools
rapidly, when leaving the combustion zone (e.g. from 1500°C to
200°C in few seconds), into spherical, glassy particles. Most of
these particles fly out with the flue gas stream and are therefore
called fly ash. The fly ash is then collected in electrostatic
precipitators or bag houses and the fineness of the fly ash can be
controlled by how and where the particles are collected.

EQUIPMENT REQUIRED
IN R. M. C.
Following are the equipments required in R.M.C
1. Batching plant
 2. Transit mixer

BATCHING
Batching plants are classified as
1. Manual
2. Semiautomatic
3. Fully automatic

STORAGE
Storage of the raw materials is done by following methods: -

INLINE BINS
Inert raw materials like fine & coarse aggregates are
stored in bins called as
“Inline Bins” where the trucks carrying fine & coarse aggregate
can dump the material easily.
The aggregates required are fed by the means of aggregate belt
conveyer. On the aggregate belt conveyer the aggregates are
weighed automatically by means of computer form the computer
room present on the plant.
Excel Plant Data
Skip Bucket (Weighing belt)

Belt conveyer
(To feed Raw material to the holding hopper)

Belt
Weigh Bridge
 Inline Bins

TRANSIT MIXER

SILOS
Cement & Flyash are stored in airtight container called as
“Silos”. The required quantity of cement & flyash is extracted
by the silos. There are two cement silos and one silo of flyash.

The capacity of cement silo is

2 x 130 tons = 260 tons

Cement and Flyash are fed to holding hopper with the help of
a screw conveyer.
 A heavy duty cement screw conveyor is fixed in inclined
position to convey the cement from Manual Feeding Hopper to
Cement Hopper. A suitable drive unit is also provided to drive
the screw

The screw conveyor body and the screw is

manufactured from heavy duty ‘C’ class pipe and the flutes are
fabricated from 5mm plate. Running clearances provided
between body and flutes for smooth running. The screw is
supported on both ends by bearing and at center by hanger
bearing having renewable hard bush. These bearing can b
adjusted with setting nuts so as to have proper alignment.

The screw conveyor is provided with suitable vertical

supports. One inlet connection is provided at the bottom en
where manual-feeding hopper is connection & one discharge
connection at the top from where the cement is discharged to
cement weighing hopper. Flexible joint is provided between
discharge connection & cement weighing hopper. Two cleaning
pockets, one in the middle and another at the bottom side are
also provided for emergency removal of cement from the
conveyor.
TECHNICAL FEATURE
FOR TRANSIT MIXER

MODEL CONMIX CONMIX CONMIX

4 5 6
NOMINAL CAPACITY 4.0m3 5.0m3 6.0m3
TOTAL GEOMETRIC 7.6m3 8.7m3 10.2m3
VOLUME
FILLING RATIO 53% 57% 59%
ENGINE (KIRLOSKAR RB33 RB44 RB44
maker)
POWER REQUIREMENT 38 52H.P./1800 56 H.P./2000
H.P/1500 R.P.M. R.P.M.
R.P.M.
DRUM SPEED 0-14 R.P.M. 0-14 0-14 R.P.M.
R.P.M.
WATER TANK 450 450 600 LITERS
LITERS LITERS
WATER CONNECTION 25mm 25mm 25mm
WATER 20m3/Hr. 20m3/Hr. 20m3/Hr.
METER(OPTIONAL)
LENGTH OF MIXER 5100mm 5700mm 5800mm
WIDTH OF MIXER 2200mm 2200mm 2200mm
HEIGHT OF MIXER 2350mm 2425mm 2500mm
WEIGTH OF MIXER 3000kgs. 3300kgs. 3500kgs.
ONLY
DRUM ANGLE 13 degree 12 degree 12 degree
HYDRAULIC 70cc/Rev. 70cc/Rev. 70cc/Rev.
PUMP/MOTOR
(SUNDSTRANI OR
REXROTH)
GEAR BOX 1:141 1:141 1:141
(ZF,SUNDSTRAND OR
EQUIVALENT)
 MIXING PROCESS
Following in are types of mixing of concrete.
1. Transit Mixed (or "truck-mixed") Concrete
2. Shrink Mixed Concrete
3. Central Mixed Concrete

1.Transit Mixed (or "truck-mixed") Concrete

While ready mixed concrete can be delivered to the point of

placement in a variety of ways, the overwhelming majority of it
is brought to the construction site in truck-mounted, rotating
drum mixers. Truck mixers have a revolving drum with the axis
inclined to the horizontal. Inside the shell of the mixer drum are
a pair of blades or fins that wrap in a helical (spiral)
configuration from the head to the opening of the drum. This
configuration enables the concrete to mix when the drum spins
in one direction and causes it to discharge when the direction is
reversed.

To load, or charge, raw materials from a transit mix plant or

centrally mixed concrete into the truck, the drum must be turned
very fast in the charging direction. After the concrete is loaded
and mixed, it is normally hauled to the job site with the drum
turning at a speed of less than 2 rpm.

Since its inception in the mid-1920's, the traditional truck-mixer

has discharged concrete at the rear of the truck. Front discharge
units, however, are rapidly becoming more popular with
contractors. The driver of the front discharge truck can drive
directly onto the site and can mechanically control the
positioning of the discharge chute without the help of contractor
personnel.

Currently, because of weight laws, the typical truck mixer is a 7

to 8.5 m3. The drums are designed with a rated maximum
capacity of 63% of the gross drum volume as a mixer and 80%
of the drum volume as an agitator. Generally, ready mixed
concrete producers, load their trucks with a quantity at or near
the rated mixer capacity. Fresh concrete is a perishable product
that may undergo slump loss depending on temperature, time to
the delivery point on the job site, and other factors.

Water should not to be added to the mix unless the slump is less
than that which is specified. If water is added, it should be added
all at once and the drum of the truck mixer should be turned
minimum of 30 revolutions, or about two minutes, at mixing
speed.
The ASTM C 94, Specification for Ready Mixed Concrete,
indicates that the concrete shall be discharged on the job site
within 90 minutes and before 300 revolutions after water was
added to the cement. The purchaser may waive this requirement,
when conditions permit.

In certain situations, air-entraining, water reducing, set-retarding

or high-range water reducing admixtures may need to be added
to concrete prior to discharge to compensate for loss of air, high
temperatures or long delivery times. The ready mixed concrete
producer will assist the purchaser in such circumstances.
2.Shrink Mixed Concrete

Concrete that is partially mixed in a plant mixer and then

discharged into the drum of the truck mixer for completion of
the mixing is called shrink mixed concrete. Central mixing
plants that include a stationary, plant-mounted mixer are often
actually used to shrink mix, or partially mix the concrete. The
amount of mixing that is needed in the truck mixer varies in
these applications and should be determined via mixer
uniformity tests. Generally, about thirty turns in the truck drum,
or about two minutes at mixing speed, is sufficient to
completely mix shrink-mixed concrete.
3.Central Mixed Concrete
Central-mixing concrete batch plants include a stationary,
plant-mounted mixer that mixes the concrete before it is
discharged into a truck mixer. Central-mix plants are sometimes
referred to as wet batch or pre-mix plants. The truck mixer is
used primarily as an agitating haul unit at a central mix
operation. Dump trucks or other non-agitating units are
sometimes be used for low slump and mass concrete pours
supplied by central mix plants. About 20% of the concrete
plants in the US use a central mixer. Principal advantages
include:

 Faster production capability than a transit-mix plant

 Improved concrete quality control and consistency and
 Reduced wear on the truck mixer drums.

There are several types of plant mixers, including:

 Tilt drum mixer

 Horizontal shaft paddle mixer
 Dual shaft paddle mixer
 Pan mixer
 Slurry mixer

The tilting drum mixer is the most common American central

mixing unit. Many central-mix drums can accommodate up to
12 yd3 and can mix in excess of 200 yd3 per hour. They are fast
and efficient, but can be maintenance-intensive since they
include several moving parts that are subjected to a heavy load.

Horizontal shaft mixers have a stationary shell and rotating

central shaft with blades or paddles. They have either one or two
mixing shafts that impart significantly higher horsepower in
mixing than the typical drum mixer. The intensity of the mixing
action is somewhat greater than that of the tilt drum mixer. This
high energy is reported to produce higher strength concrete via
to thoroughly blending the ingredients and more uniformly
coating the aggregate particles with cement paste. Because of
the horsepower required to mix and the short mixing cycle
required to complete mixing, many of these mixers are 4 or 5
yd3 units and two batches may be needed to load a standard
truck or agitator.

Pan mixers are generally lower capacity mixers at about 4 to 5

yd3 and are used at precast concrete plants.

Slurry Mixing
The slurry mixer is a relative newcomer to concrete mixing
technology. It can be added onto a dry-batch plant and works by
mixing cement and water that is then loaded as slurry into a
truck mixer along with the aggregates. It is reported to benefit
from high-energy mixing. Another advantage is that the slurry
mixer reduces the amount of cement dust that escapes into the
air.
 TESTS CARRIED ON R.M.C
All the ingredients used for preparation of the concrete, are
thoroughly tested for their quality and physical properties in a
well equipped laboratory attached to the plant for conformity to
relevant Indian Standard Codes.
The moisture probe determines the water content in the sand and
aggregates. This accordingly helps in fixing the proportion of
water to be added for the preparation of the mix.
The sand being used is passed through the mechanized sieving
system, before feeding for mixing.
Trial mixes are carried out and tested to ensure that each and
every batch of concrete coming out of the plant meets the
parameters of client’s requirements
The sand being used is passed through the mechanized sieving
system, before feeding for mixing.

TESTS ON FINE AGGREGATES

1. Sieve Analysis
2. Specific Gravity
3. Bulk Density (Loose / Rodded)
4. Silt Test by Volume / Weight
5. Water Absorption
6. Sulphite / Chloride / Alkali Reactivity
7. Organic Impurities
 TEST ON COARSE AGGREGATES

1. Sieve Analysis
2. Specific Gravity
3. Aggregate Impact Value
4. Bulk Density (Loose / Rodded)
5. Water Absorption
6. Flakiness Index
7. Elongation Index
8. Alkali Reactivity
9. Abrassion Test
10. Crushing Test

TEST ON WATER
1. pH Value
2. Chloride
3. Sulphite
4. Nitrite

TEST ON FRESH CONCRETE

1. Workability
2. Temperature

TEST ON HARDENED CONCRETE

1. Compressive Strength
2. Flexure Strength

TEST ON ADMIXTURES
1. Air entrained
2. Specific gravity
VARITIES OF CONCRTETE IN
R.M.C
1. Normal Strength Concrete (NSC)
 Composition: Consists of standard ingredients—cement, aggregates, water,
and sometimes admixtures.

 Strength: Typically used in general construction where high strength isn't a

primary requirement.

 Applications: Foundations, slabs, sidewalks, and most common construction

projects.

2. High-Strength Concrete (HSC)

 Composition: Contains a higher ratio of cement and lower water-to-cement
ratio for increased strength.

 Strength: Exhibits significantly higher compressive strength, suitable for

high-rise buildings, bridges, and heavy-duty structures.

 Applications: Tall buildings, bridges, industrial structures requiring high

load-bearing

3. Self-Consolidating Concrete (SCC)

 Composition: Modified mix design with high flowability and self-leveling
characteristics.

 Properties: Doesn’t require mechanical vibration for placement, ideal for

complex structures and congested reinforcement areas.

 Applications: Architectural concrete, heavily reinforced structures, precast

elements.

4. Fiber-Reinforced Concrete (FRC)

 Composition: Contains short discrete fibers (steel, glass, synthetic) to enhance
toughness and durability.

 Properties: Improved resistance against cracking and impact, used in seismic

areas or for enhanced durability.

 Applications: Pavements, bridge decks, tunnels, and industrial floors.

 5. Lightweight Concrete
 Composition: Uses lightweight aggregates (expanded clay, shale, or slag) to
reduce density.

 Properties: Lower density provides better insulation, reduces dead load on

structures, and improves workability.

 Applications: Roof decks, precast panels, sound barriers, where reduced

weight is beneficial.

6. High-Performance Concrete (HPC)

 Composition: Advanced mix design with optimized gradation and
supplementary cementitious materials.

 Properties: Exceptional strength, durability, and workability, often used in

demanding environments.

 Applications: Highways, bridges, marine structures, and critical infrastructure

projects.

7. Decorative Concrete
 Composition: Various aggregates, pigments, and surface treatments for
aesthetic appeal.

 Properties: Offers a wide range of textures, colors, and patterns.

 Applications: Stamped concrete, colored concrete, exposed aggregate finishes

for decorative purposes in landscapes, architectural elements.

8. Pervious Concrete
 Composition: Low water-to-cement ratio with minimal fines content for
permeability.

 Properties: Allows water to pass through, minimizing runoff and aiding

groundwater recharge.

 Applications: Parking lots, sidewalks, and areas requiring stormwater

management.
 SUSTAINABILITY OF
CONCRTETE IN R.M.C

1. Alternative Materials and Supplementary

Cementitious Materials (SCMs)
 Fly Ash, Slag, and Silica Fume: These industrial by-products are
used as supplementary materials in cement production, reducing
the need for clinker (a major source of CO2 emissions).

 Recycled Aggregates: Crushed concrete or other recycled

materials can substitute for natural aggregates, reducing extraction
and waste.

2. Low-Carbon Cement Production

 Calcined Clays and Limestone Calcined Clay Cement (LC3):
Blends of clays and limestone with lower kiln temperatures can
substantially reduce CO2 emissions during cement production.

 Alternative Binders: Researchers are exploring alternatives to

traditional cement, such as geopolymers, which have lower carbon
footprints.

3. Green Concrete Mix Designs

 Reduced Cement Content: Optimizing mix designs by reducing
cement content while maintaining performance can significantly
lower embodied carbon.

 Use of Admixtures: Employing admixtures like water reducers or

superplasticizers allows for the production of high-performance
concrete with less water and cement.
 4. Carbon Capture and Utilization (CCU)
 Carbonation of Concrete: Over time, concrete can absorb CO2
from the atmosphere, a process called carbonation, which can
offset some of its initial carbon emissions.

 Direct Air Capture (DAC) Technology: Some initiatives explore

capturing CO2 directly from the atmosphere and using it in
concrete production.

5. Enhanced Durability and Longevity

 Design for Durability: Creating concrete with improved durability
characteristics reduces the need for repairs or replacements, thus
reducing overall environmental impact.

 Self-Healing Concrete: Innovations in self-healing materials,

where concrete can autonomously repair cracks, contribute to
extended service life.

6. Construction Practices and End-of-Life

Considerations
 Recycling and Reuse: Strategies for recycling demolished
concrete into new construction or using it as a base material
minimizes waste.

 Deconstruction Planning: Considering future deconstruction and

the recyclability of materials at the design stage can reduce
environmental impact during building removal.
 CHALLENGES OF CONCRTE
MANUFACTURING
INDUSTRY
Reduction in CO2 emissions
The cement production process is associated with high CO2
emissions. Therefore, it is necessary to take the required actions to
transition to a carbon-neutral model. An example is the Roadmap
of the Spanish cement industry to achieve climate neutrality
by 2050, which affects 5 industries: Clinker, Cement, Concrete,
Construction and Re-Carbonation. Proposals to achieve this
include the use of biomass fuels, hydrogen, and electrification.

Use of clean energy in logistics

In line with the previous point and to contribute to the
objective of reducing carbon emissions, sustainable
alternatives are also sought for inland transport. This involves
neutral internal transports (electric and/or hydrogen-powered).
Beyond production, the goal is to minimize the use of non-
fossil fuels.

Digital identity for traceability

Cement loses its physical identity when it becomes a by-product.
It is necessary to advance its capability to identify the digital
identity of cement which can ensure the traceability of the product
together with its mechanical and environmental performance. This
allows for adequate tracking during any stage of the chain
independent from agents.
Automation and digitalization of production
The Association of Cement Manufacturers of Spain (Oficemen)
and Simens raise the need for transformation in the Smart
Cement Industry 4.0. Production should increase the automation
and digitalization of operations, including the use of sensors,
remote diagnoses, analysis of big data (including the artificial
intelligence analysis of unstructured data such as images and
video), equipment, virtual facilities, and intelligent control
systems (based first on 'knowledge capture' and then on machine
learning). This allows for system optimization and increased
efficiency gains in production.

Increased information security

Digitalized production along with the inclusion of remote-
operated plants while also using artificial intelligence, generates
an increased vulnerability in systems and will leave the industry
exposed to computer threats. This will require increased
information security standards and procedures. This should be a
priority for companies who want to be on a path towards self-
governing factories.

Interconnectivity and information in real

time
Coordination between the different members of the chain is
fundamental. Suppliers, inputs, and services used in the
manufacturing of cement should have a real-time connection with
cement manufacturers, and thus be able to respond promptly to
your requests. This will enable them to know the forecasts of
consumption and even detect in a timely manner the need for the
replenishment of supplies. In turn, it will provide the factory with
information about the needs of its customers and will allow for
production planning that is more accurate and optimized.
The cement industry faces substantial challenges in the coming
years. Addressing the technological transformation can become a
differentiating factor and a strategic advantage.

ADVANCEMENT OF
CONCRTE TECHNOLOGY
 1. Project Management Software

 2. BIM

 3. Artificial Intelligence (IoT)

 4. UHPC

 5. Self-healing concrete

 6. Graphic concrete

 7. Light-generating concrete

 8. Translucent cement

 9. Drones

 10. 3D Printing

 11. Off-site construction

 1. Project Management Software
There is construction management software made specifically for concrete
contractors. For commercial construction projects, concrete and masonry
contractors set the foundation. They provide services that range from site
prep to finishing, timely delivery, and quality. With traditional processes, it
can result in significant project delays that can cost additional money and
time. With concrete construction project management, you can track real-
time labor and production. You no longer have to wait for payroll or
accounting reports to be processed.

2. BIM
Building Information Modeling has been around for decades, but technology
is forever advancing. Its 3D modeling design software allows professionals
the tools to see their project’s design, plan, and construction. Using BIM can
help communicate the scope of the concrete project across all parties.
Concrete contractors have been trying to push towards 3D, forming from 2-
d for fieldwork. The entire building process becomes more efficient because
there is an increase in communication with field workers, and they can see
as-built formwork. BIM overall has the benefits to improve the supply chain
and reduce waste, delays, and mistakes.
 3. Artificial Intelligence (IoT)
GPS trackers and IoT sensors on equipment for concrete construction allows
for predictive maintenance and can improve production cycles. Intelligent
equipment is one of the newer concrete construction technologies because it
can use human knowledge through computer processes. Adding sensors to
equipment gives field workers more accurate and timely information about
their assets, so there is no need for second-guessing!

4. UHPC
Ultra-High Performance Concrete is a newer concrete technology that
contains fibers but consists of mostly 80% traditional concrete. These fibers
range in strength from polyester to stainless steel and ultimately deliver
durability and strength to the final product. Additionally, UHPC has a longer
lifespan than traditional concrete; it’s up to more than 75 years, and
traditional concrete has 15-25 years. The United States is one of the key
market players for UHPC. Also, the UHPC global market has an expected
CAGR of 8.3% from 2019 to 2024 with a growth of USD 369 Million in
2019 to 550 Million in 2024.

5. Self-healing concrete
After construction, concrete cracks, weathers, leaks, and bends. Self-healing
concrete contains limestone producing bacteria that repairs the crack when it
comes into contact with air and water. Along with concrete, this self-healing
bacteria can repair mortar for already existing structures. Repetitive dry and
wet cycles with a width of 0.05 to 0.1mm completely seal cracks. The self-
healing product acts as a capillary, and the water particles go through the
cracks. Then, these water particles soak and hydrate the cement, causing it
to expand, thus filling the crack. However, if cracks are greater than the
width of approximately 0.1mm, other reconstructive work will be required.

6. Graphic concrete
According to the Kimmo Knappila, the CEO of Graphic Concrete LTD,
“graphic concrete offers architects the versatility to deliver distinctive,
intriguing, and iconic imagery to precast concrete surfaces.” Graphic
concrete technology is the printing of a visual idea on a specific membrane
and transferring it to a precast concrete surface. The membrane is disposable
and moldable in any shape or form. This new trend in concrete technology
allows custom concrete patterned surfaces. With graphic concrete, you can
customize and add color pigments and different colors to enhance patterns
and designs.

Graphic concrete can go on already prefabricated concrete products.

Typically, graphic concrete is applied to sound barriers, pavers, facades, and
interior applications. Graphic concrete is cost-effective in comparison to
other precast concrete surfaces. When finished, they are ready to use, so you
don’t need additional coating or surface treatments. Overall, graphic
concrete can reduce construction time and keep costs down over the build.
 7. Light-generating concrete
Jose Carlos Rubio Avalos developed this trend in concrete technology. This
type of cement can absorb and radiate light. In terms of energy usage, it uses
much less because this cement can be created at room temperature. During
the day, the cement absorbs solar energy, and then it can expend light for
approximately 12 hours. Now you’re thinking, how does this cement absorb
solar energy? The cement does not have the crystallization supplement, and
instead has a gel consistency; this allows light to pass inside.

This type of cement doesn’t require electricity, so it is typically on

roadways, bridges, bike paths, and more. This is an eco-friendly alternative
because the gas release in the manufacturing process is water vapor. The
lifespan of light-generating concrete is about 100 years. Many light-
generating concrete products emit blue or green light so that they can light
roads and bridges. During production, to ensure safer environments for
drivers, cyclists, and pedestrians, you can adjust the brightness level.

8. Translucent cement
Translucent concrete and cement are transferring the architectural look. This
cutting edge technology consists of “fiber optics sandwiched between layers
of insulation and concrete.” These fibers allow light from the outside to
transmit to the inside and vice versa. Translucent cement is customizable for
the structural and design requirements for the project. By this, you can
determine the diameter and density of the fibers, and this determines how
transparent the concrete will be. Instead of plain, regular concrete,
translucent cement is chosen by designers and architects to add design
aspects to structures like stairs and partition walls.

9. Drones
Drones are one of the new trends in concrete technology and its usage is
increasing on construction sites, and we can expect the usage to increase
exponentially. Primarily, drones survey and inspect sites from an aerial view
that the contractor cannot. Drones finish inspections in a fraction of the time
it would take traditionally. Although some construction companies were
reluctant to use drones, the outcomes have benefited them immensely. For
concrete professionals, drones are beneficial because they can help optimize
layouts through digitation. Drones ensure that projects stay on track with the
ability of increased visibility to spot potential problems.

In 2019, the Spanish architecture firm MuDD used drones to spray a

cement-like substance onto fabric to “construct lightweight structures.”
drones eliminated expensive construction equipment and sped up the
process. It only took them five days to build the prototypes; traditionally, it
might have taken them weeks. The prototype included a quadcopter drone to
pray shotcrete onto fabric. For effective application of shotcrete, you
typically need human operators and a crane, but with this method, you
maneuver a drone to do the work.
 10. 3D Printing
3D printing is not just limited to plastic and metal. With recent
developments, concrete 3D printing offers the possibility in the quick build
of affordable homes and communities. For concrete contractors and
architects, 3D concrete printing is appealing because they can produce less-
expensive buildings with less time, and handle higher dimensional analytics
compared to traditional construction techniques.

Benefits of 3D concrete printing:

— low cost

— high build speed

— reduced waste

As this is one of the newer trends in concrete technology, it is not commonly

used in large-scale projects. This is because this type of technology is a
better fit with mid-sized buildings, structures at a low price, and quicker
time span. 3D concrete printing is more eco-friendly, meaning very little
material waste during the construction process compared to traditional
builds. Instead of the architect or designer converting their blueprints to
make molds, 3D concrete printing saves energy, time, and money by the
printer’s ability to read 3D blueprint codes and immediately start printing.
More and more companies will adopt 3D concrete printing to reduce costs,
produce complex structures, and reduce production time.

11. Off-site construction

Off-site construction is the design, fabrication, and assembly of components
at a different location than the actual installation site. Precast or
prefabricated concrete is the most common type of off-site concrete
techniques. Because the number of skilled labor is low, off-site construction
is ideal because it is efficient, improve safety, reduce costs, increase speed,
and its quality is consistent. As mentioned earlier, UHPC, Ultra-High
Performance Concrete is very adhesive, which makes it compatible for use
in prefabricated bridge elements and systems (PBES). With this system, you
build bridge components like deck and beams, off-site, at a different
location, and then install in the final location.

MERITS OF R. M. C.
 Better quality concrete is produced.

 Elimination of storage space for basic materials at site.

 Elimination of Procurement / Hiring of plant and

machinery

 Wastage of basic materials is avoided.

 Labour associated with production of concrete is

eliminated

 Time required is greatly reduced

 Noise and dust pollution at site is reduced.

 Organization at site is more streamlined.

 Durable & Affordable

 No storage space required either for raw materials or for

the mix

 Lower labour and supervisory cost

 No wastage at site

 Environment friendly
o Availability of concrete of any grade

DEMERITS OF R. M. C.
1. Need huge initial investment.

2. Not affordable for small projects (small quantity of

concrete)

3. Needs effective transportation system from R.M.C to

site.

4. Traffic jam or failure of vehicle creates problem if

proper dose of retarder is not given.

5. Labours should be ready on site to cast the concrete in

position to vibrate it and compact it.
 CONCLUSION
Ready Mix Concrete plant is a modern technique of

production of concrete in large quantities away from the actual

site of placing. It is very useful in cities where demand of

concrete is very high and construction sites are in congested areas

where mixing on site is not possible. It is suitable for projects like

Dam, Roads, Bridges, commercial complex, Malls and all types

of mass construction where time limit plays a vital role and where

demand is huge.
 PROJECT REPORT
Location of project : Godrej Construction
RMC Batching & Mixing Plant
Survey No. 124/125,
Godrej Industries,
Vikhroli, District Mumbai.
Maharashtra. India.

Plant Manager : Mr. Nishant Chandethakkar

Deputy Manager (QC): Mr. Prashant Gawde

PROJECT TEAM MEMBERS WITH PLANT MANAGER

MR. NISHANT CHANDETHAKKAR &

DEPUTY MANAGER (QC)

MR. PRASHANT GAWDE AT GODREJ RMC PLANT

VIKHROLI, MUMBAI.