INTRODUCTION

1. RMC is a specialized material in which the cement aggregates and other

ingredients are weigh-batched at a plant in a central mixer or truck mixer,
before delivery to the construction site in a condition ready for placing by the
builder. Thus, `fresh' concrete is manufactured in a plant away from the
construction site and transported within the requisite journey time. The RMC
supplier provides two services, firstly one of processing the materials for
making fresh concrete and secondly, of transporting a product within a short
time.

2. The main difference between the concrete found in these classical

civilizations and modern ready mixed concrete is the binding agent. The
Egyptians used crushed gypsum, the Romans knew how to make lime by
burning crushed limestone and they even discovered that adding volcanic ash
or old bricks and tiles improved the setting characteristics of their cement.

3. Today, Readymix concrete comprises a mix of aggregates, cement, water

and a variety of admixtures. Understanding these individual ingredients in a
little more detail provides an insight into ways of obtaining the best results for
different types of project.

4. 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.

5. Ready mix concrete manufacturers use the same cement, aggregate,

additives and water, but the product is created off-site and usually delivered
in bulk to the construction zone. Large trucks with revolving hoppers replace
the smaller rented versions used directly on the site. Ready mix concrete is
ordered directly from a local supplier who can create custom blends or bulk
orders. Some contractors may need more aggregate in their concrete, for
example, or special curatives added for faster drying times.

6. Ready mix concrete companies often belong to professional

organizations which oversee all of their members. Any innovation in the ready
mix concrete industry can be quickly implemented or discussed during
regular meetings. Other issues which can affect the ready mix concrete
industry are maintaining professional standards, environmental concerns and
local laws concerning heavy transportation.

7. It is not unusual to find ready mix concrete companies in the industrial

sections of cities or in rural areas. Massive piles of sand, gravel and other
aggregates are usually stockpiled on the grounds, along with earthmoving
equipment and delivery trucks. Companies which specialize in ready mix
concrete may also provide gravel for roadway construction and cement for
other construction projects.

AIM
8. The aim of this paper is to unfold various aspects of ready mix concrete
and helping in good decision making both in establishment and production by
an extensive market survey.

2
WHAT IS READY MIX CONCRETE?
9. Ready Mixed Concrete, or RMC as it is popularly called, refers to
concrete that is specifically manufactured for delivery to the customer's
construction site in a freshly mixed and plastic or unhardened state. Concrete
itself is a mixture of Portland cement, water and aggregates comprising sand
and gravel or crushed stone. In traditional work sites, each of these materials
is procured separately and mixed in specified proportions at site to make
concrete. Ready Mixed Concrete is bought and sold by volume - usually
expressed in cubic meters. RMC can be custom-made to suit different
applications.

10. Ready-mix concrete is a type of concrete that is manufactured in a

factory or batching plant, according to a set recipe, and then delivered to a
work site, by truck mounted transit mixers. This results in a precise mixture,
allowing specialty concrete mixtures to be developed and implemented on
construction sites. The first ready-mix factory was built in the 1930s, but the
industry did not begin to expand significantly until the 1960s, and it has
continued to grow since then.

11. The leading ready-mix concrete supplier worldwide is the Mexican

concrete company Cemex; its main competitor is France-based Lafarge and
the leading ready-mix concrete supplier in Middle East is the Unibeton Ready
Mix.

13. The Ready mixed concrete company is required to equip themselves

with up-to-date equipments, such as transit mixer, concrete pump, and
Concrete Batching Plant, which needs visualized production management
software and also PLC controller. Ready Mixed Concrete is manufactured
under computer-controlled operations and transported and placed at site
using sophisticated equipment and methods. RMC assures its customers
numerous benefits.

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HISTORY OF READY MIX CONCRETE
14. First introduce by Architect Jurgen Heinrich Magens, he get his patented
of RMC in Germany in 1903.

15. Concrete is the most widely used construction material in the world and
with a 9000-year history it has played a major part in shaping modern
civilization. The Romans were particularly adept at using concrete but it was
also known to the Egyptians and in a primitive form to Neolithic civilizations.
Modern concrete was developed after the discovery of Portland cement. First
patented in 1824 but not developed in its present form until 1845 when
higher kiln temperatures were achieved, Portland cement made new forms of
construction possible.

16. Despite these advances attempts to supply the building trade with ready
mixed concrete on-site foundered until the late 1920’s when delivery trucks
were fitted with a drum that agitated the concrete while on the move. In the
UK, the first Readymix operation was set up in 1930 and by the 1960’s a
successful national network of concrete plants was firmly established.

17. The first concrete mixed off site and delivered to a construction site was
effectively done in Baltimore, United States in 1913 just before the First World
War.

Figure: Transit mixer in late 1940’s and Concrete pump in late 1940’s (Ambuja Cement
Literature Vol. 90)

4
18. The first concept of transit mixer was also born in 1926 in the United
States. In 1939, the first RMC plant was installed in United Kingdom and in
1933 first specifications on RMC was published in United Kingdom.

19. In Bangladesh RMC was first used in 1993 by CONCORD.

20. RMC was successfully established sometime after 1998 in Bangladesh,
especially at Dhaka and Chittagong.
21. As per the available record up to 2010, there are around 76 RMC plant
major cities with a total capacity of around 1200 CuM/hr, producing 1.8
million cubic meter of concrete per year.

SCOPE OF RMC IN BANGLADESH

22. A technical study report on the development of market for bulk
cement in Bangladesh was made in 1996, proved to be positive
development towards modernization of cement distribution system
in Bangladesh, including setting up Ready mix concrete Plants. The
objective of this technical study was to formulate an action plan for
the development of market for bulk cement in large cement centres
in Bangladesh and for gradual shift. from the traditional mode of
transportation in bags to bulk transportation through setting up of
ready mixed concrete plants in different parts of the country. The
recommendation of the action plan provided a useful guidance
towards expanding bulk cement market thus paving a way for
installation or ready mixed concrete plants in Bangladesh.
23. According to Cement Manufacturers Association, RMC is being
increasingly recommended for all major public construction work
such as highways, flyovers. In Bangladesh it can grow to consume
40-45 percent of cement by 2020 through setting up of RMC plants
in various consumption centers.

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24. According to European Ready Mixed Concrete Organization
(ERMCO), the marketing of RMC should no more be in terms of
strength grades only, but a combination of strength durability
classification as per the Concrete Codes which improves the sell
ability of RMC in terms of the requirements of the projects.
Appropriate environmental, safety and health regulations for the
working force need to be kept in mind in the management and
operation of RMC.

ADVANTAGES AND DISADVANTAGES

25. Advantages.
a. A centralized concrete batching plant can serve a wide
area.
b. The plants are located in areas zoned for industrial use,
and yet the delivery trucks can service residential districts or
inner cities.
c. Better quality concrete is produced.
d. Elimination of storage space for basic materials at site.
e. Elimination of procurement / hiring of plant and
machinery
f. Wastage of basic materials is avoided.
g. Labor associated with production of concrete is
eliminated.
h. Time required is greatly reduced.
j. Noise and dust pollution at site is reduced.
k. Reduces cost.

26. Disadvantages.
a. The materials are batched at a central plant, and the
mixing begins at that plant, so the traveling time from the plant
to the site is critical over longer distances. Some sites are just
too far away, though this is usually a commercial rather than
technical issue.
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b. Generation of additional road traffic; furthermore, access
roads, and site access have to be able to carry the weight of the
truck and load. Concrete is approx. 2.5tonne per m³. This
problem can be overcome by utilizing so-called 'mini mix'
companies, using smaller 4m³ capacity mixers able to access
more restricted sites.
c. Concrete's limited time span between mixing and going-
off means that ready mix should be placed within 120 minutes
of batching at the plant.
d. It is cost effective. Modern additives modify precisely that
time span however, the amount of additive added to the mix is
very important.

7
PRODUCTION OF READY MIX CONCRETE

8
READY MIX CONCRETE PLANT
27. General Processing Information.

a. Description of manufacturing Process.

b. Flow Chart of Manufacturing Process.

28. Brief Description of Equipments.

a. Description of Machinery.
(1) Bins for sand, aggregate, cement: properly designed to fit
with the mixing machine.

(2)Conveyor for sand, aggregate: different width 600mm, 750mm,

900mm, 1000mm, 1200mm etc.

9
 (3) There are three types and each type has its main
mixing machine:

(a) Silo Type Mixer.

(b) Pan Type Mixer.
(c) Twin Shafts Mixer.

(4) Capacity of mixing machine: From 0.5m3 to 3.0m3.

(5) Computer control System.
(a) Jobsite system. Simple, with few functions.
(b) Professional type. computer system with more
memories and monitors.
(6) Carriers. agitator trucks

b. Testing Machinery .
(1) Quality control. Inspection of raw materials and finished
products is necessary. Proper laboratory test equipment should
be provided to customers.

c. Control Panel.
(1) "SCADA" Based Controller Proxy switch for each control
point (Gates).
(2) Display Monitor.
(3) Storage for 99 different type of mix proportions.
(4) Preset batch controls the no. of batches for a transit mixer.
(5) Provision for printing operating data like - Mix Proportion,
Batch weight, total no. of Batches, Sub total, Gross Total etc.
(6) Automatic & Manual control.
(7) 12' x 7' cabin size.

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29. Manpower Requirement.

A B C D
Job-site Job-site Professional Professional
Type Type Type Type
2.0m 3 3.0m3
0.5m3 0.5m3
Worker 1 1 1 1
Operator 1 1 1 1
Q/C ＊ ＊ 1 1
Engineer ＊ ＊ 1 1
Controller ＊ ＊ 1 1
Truck diver 1-2 1-2 5-10 5-10

＊ Should be modified by the real conditions.

＊ Each personnel should have proper knowledge and skillful
experiences in order to do the job well.

30. Utilities.
a. Depends on the design.
b. Electric power ranging from 100KW-500KW.
c. Water requires from 50Liter to 200 Liter per minute.

31. Analysis on Product Cost & Profit. In each country the prices of
materials, labor, land etc are different; thus, the selling prices are also
different. The following are some major items for cost analysis and for more
details; the customers should rely on professional consultants.

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 a. Monthly Income Statement (Estimated).

Sales Selling price x Volume A

Cost of goods 1. Material(sands, aggregates, B
sold cements…etc.)
2. Labor
3. Depreciation for equipments and
factory building
4. Other over-head
Operating Office expenses (including personnel), C
Expenses Rental, Bank interest expenses and
other over-head expenses
Estimated E=A-(B+C)
income

b. Return on Investment (Estimated).

＊Total investment= Land cost + equipments + factory +
operating cash = F
＊Return on Investment= F/E=G (How many month to get
investment back)

32. Environmental Concern.

The cement dust and wasted water should be re-collected by equipments.

12
33. Plant Layout.

a. 0.5m3 to 1m3.

b. 2m3 to 3m3.
13
14
COST ANALYSIS
34. Raw Materials.
a. Stone.
(1) ¾ inch.
(2) ½ inch.
(3) ¼ inch.

¼ inch ¾ inch ½ inch

b. Sand.
c. Cement.

b. Place and type of stone.

Place Type of Stone (Colour)

Jaflong White
Volagonj Black and White
BistakandiGoainghat Gray/Clay colour
Sharfin Red
Utma Black

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c. Order of Strength.
(1) Volagonj.
(2) Utma .
(3) Jaflong.
(4) Sharfin.
(5) Bistakandi Goainghat .

d. Costs of various types of stone(per cft).

Place ¾ inch (BDT) ½ inch (BDT) ¼ inch (BDT)

Volagonj 90-92 66 45
Bistakandi 80-82 60-64 40
Jaflong 84-85 60-61 39-40
Utma 72-74 55

Stone of Sharfin is used for just mixing.It is not for sale.

e. Costs of Transportation by Truck (per cft).

To From Jaflong From Sylhet (BDT)

(BDT)
Dhaka 32 32
Chittagong 39 34
Cox’s Bazar 47-50 42-45

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39. Sand.
a. costs of sylhet sand (Gabtali , Dhaka)

Name Area (From) Price (per cft)

Bengal Enterprise Shunamganj 20/-
Fajilpur 20-21/-
Sripur 18/-
Riad Enterprise Shunamganj 20/-
Fajilpur 22/-
Sripur 17/-

b. Carrying Expense.
(1) Truck Fair ( From Gabtali, Dhaka)
Area Fair
Dhanmondi 800/-
Mirpur 900/-
Farmgate 950/-
Gulshan 1000/-

(2) Sylhet Sand (Sylhet)

Area (From) Price (per cft)

Shunamganj 10-14/-
Fajilpur 12-15/-
Sripur 10-15/-
Jaintiapur 10-13/-
Lalakhal 11-14/-

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40. Cement.

a. Cost Of Various Brands Of Cement.

Brand name Prices per cft

Scan 328/-
Holcim 332/-
Fresh 304/-
Tiger 296/-
Shah 320/-
Crown 312/-
Sevenrings 304/-

41. Labour And Training Cost.

a. RMC companies generally uses skillful labor.
b. They give training to the labor.
c. Labors are paid monthly.
d. For those skillful labor companies generally paid 6000 to 8000/-
per month.

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42. Delivery Cost. Using Shah Cement (for various strength in psi), the
delivery costs are listed below:

Strength (psi) Material Rate Pump charge Total

(per cft) (per cft) (per cft)

2500 A Grade brick 180/- 5/- 185/-

chips(khoa)
3000 100% shingles 180/- 5/- 185/-
3000 50% bhuto and 190/- 5/- 195/-
50% shingles
3000 100% boulder 195/- 5/- 200/-
crushed
Strength (psi) Material Rate Pump charge Total
(per cft) (per cft) (per cft)
3500 100% boulder 205/- 5/- 210/-
crushed
4000 100% boulder 215/- 5/- 220/-
crushed
4500 100% boulder 225/- 5/- 230/-
crushed
5000 100% boulder 235/- 5/- 240/-
crushed

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43. Transportation Cost. Transportation cost for 1 m3 ready mix concrete
from Savar is listed bellow.

Area Tk

Tongi 125/-
Abdullapur 125/-
Uttara 150/-
Dhanmondi 170/-
Gulshan 200/-

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COMPARATIVE STUDY
44. Production

FIELD MANUAL MIXING READY MIX CONCRETE

CONCRETE

At batching plant
RAW MATERIAL Requires near mixture

Manual Computerized
WEIGHTING
Approximate Automatic
MOISTURE
CONTENT

Manual(approx.) Computerized
WATER CEMENT [not uniform]
RATIO

Manual(approx.) Computerized
DOZING OF [not uniform]
ADMIXURE

Tilting mixture Pan mixture/Single shaft

MIXING

Only approximate Auto timer

MIXING TIME

140 Liter 500 Liter

BATCH SIZE

Platform Transit mixture/Pump

DISCHARGE

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 3 cu.m. /hr. per mixture 30 cu.m. /hr. per mixture
RATE OF
CONCRETING

45. Quality.

FIELD MANUAL MIXING READY MIX CONCRETE

CONCRETE
Fair Excellent
DEGREE OF CONTROL

Variable Consistent
YIELD

Rare/ Every batch

TESTING FRESH Once in 25 batch
CONCRETE

46. RAW MATERIALS.

FIELD MANUAL MIXING READY MIX CONCRETE

CONCRETE
SELECTION/SOURCING Client/Contractor RMC Expert

Client/Contractor/ RMC Expert/Lab attached

TESTING No lab facility with plant

Multy location Single point

STORAGE

Large Limited area

SPACE REQUIREMENT

47. Placing.

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MODE Manual/hoist/Crane Concrete pump

RATE 3 cu.m. 30 cu.m.

48. Time.

a. For Construction. One of the most important fact that makes

the ready-mix concrete different from manual mixing is that it speeds
up the entire construction process as it doesn't take the time or
manpower to mix concrete on site. Rather than wasting time over
perfecting a concrete mixture, ready-mix concrete can be made to order
according to any recipe, including specialty concretes, within hours.
Single batching plants in a central location can easily serve a wide area
of commercial, industrial and residential zones, saving time on
construction projects.

b. For Transportation. Generation of additional road traffic;

furthermore, access roads, and site access have to be able to carry the
weight of the truck and load. Concrete is approx. 2.5tonne per m³. This
problem can be overcome by utilizing so-called 'minimix' companies,
using smaller 4m³ capacity mixers able to access more restricted sites.

C. Concrete's limited time span between mixing and going-off means

that ready-mix should be placed within 120 minutes of batching at the
plant.

49. Quality Basing on Mixing Method. Opting for ready-mix

concrete will help keep the overall costs down by saving your project's
valuable resources, including materials, storage space and manpower. In
addition to saving resources, ready-mix concrete also reduces pollution
outputs from construction sites, such as the dust created when mixing
concrete on site and the unnecessary waste created by making more than you
need. You also don't have to worry about obtaining the machinery and
workers needed to mix concrete on site, which results in overall lower costs
and saved resources.

23
50. Durability. Durability is the ability to last a long time without
significant deterioration. A durable material helps the environment by
conserving resources and reducing wastes and the environmental impacts of
repair and replacement. Construction and demolition waste contribute to
solid waste going to landfills. The production of new building materials
depletes natural resources and can produce air and water pollution. In ready
mix concrete, using of different admixture, appropriate material raio &
appropriate compactness assured the durability of any structure.

51 Flood Resistance. Concrete is not damaged by water; concrete

that does not dry out continues to gain strength in the presence of moisture.
That is why the proper ratio of all the ingredients should be maintained for
production of concrete. Concrete submerged in water absorbs very small
amounts of water over long periods of time, and the concrete is not damaged.
In flood-damaged areas, concrete buildings are often salvageable. Concrete
dams and levees are used for long-lasting flood control. But if the binding
materials are not mixed properly with the coarse and fine aggregate the water
resistance capability of the concrete goes off. So ready mix concrete always
makes an way to reach the concrete in the required place and resisting flood.

24
ADMIXTURES
52. Definition. Admixtures are natural or manufactured chemicals which
are added to the concrete before or during mixing. The most often used
admixtures are air-entraining agents, water reducers, water reducing
retarders and accelerators.
53. NAMES OF ADMIXTURES.
a. Rheobuild 1125
b Rheobuild 623
c. Rust Converters
d. Color Hardeners
e. Accelerators & Retarders
f. Integral Waterproofing compounds (IWC)
g. Air entraining Agents & Foaming Agents
h. Admixtures for Concrete Pavers Block Industry
j. Release agents for decorative Concrete

54. Admixture Producers.

a. BSF.
b. BORAL.
c. CIKA.
55. Why Use Concrete Admixtures. Admixtures are used for one
purpose: to improve some characteristics of the concrete. This section will
include admixtures that can be used to provide the following results:
a. Protect Against Freeze Thaw Cycles Improve Durability
b. Water Reduction in the Mix
c. Mid-Range water reducers

25
 d. High-Range water reducers super plasticizers
e. High Strength Concrete
f. Corrosion Protection
g. Set Acceleration
h. Strength Enhancement
j. Set Retardation
k. Crack Control (shrinkage reduction)
l. Flow ability
m. Finish Enhancement
n. Fly Ash- Making Concrete Stronger, More Durable, and Easier to
Work With
p. Silica Fume: Early Strength and Reduced Permeability
Produce a fluid backfill, which flows easily and is self leveling.

56. Types Of Admixtures.

a. Accelerating admixtures.
b. Retarding admixtures.
c. Water reducing admixtures.
d. Air entraining admixtures.

57. Accelerator. Accelerators are used to reduce the set time of

concrete and increase early strength gain. Although the mechanism is not fully
understood, it is believed that accelerating admixture increases the reactivity
and hydration of C3S and C2S. The reaction is catalytic in nature, forming CSH
(calcium silica hydrate) gel and increasing rate of reaction. This results with
increased reaction of Hydrates, especially at early ages.

58. Retarder. Retarders are admixtures that cause a decrease in the

rate of cement hydration and lengthen the time of setting. Retarders remove
the tendency of some cement to exhibit false set and counter the accelerating
effect of high temperatures. They improve the workability and the
finishability in hot weather and increase the transporting distance of the
ready-mixed concrete. Retarders help to reduce the possibility of early dry-

26
shrink cracking and reduce the maximum temperature rise in mass
concreting, by extending the heat-dissipation period.

59. Water Reducing Admixtures.

a. A Water-Reducing Admixture is an admixture that either increase
slump of freshly mixed concrete or mortar without increasing water
content or maintain slump with a reduced amount of water—the effect
being due to factors other than air entrainment.
b. It is a product that can be used as a water reducer, plasticizer,
workability agent or surface active agent
c. Water reducer. Aa product that will require less water to
maintain in a given slump, results in reduced w/c ratio and adds
improved strength and durability.
d. Plasticizer. A liquid or dry material that will facilitate the
handling and/or processing of the final product into which it is
blended.

60. Air-Entraining Admixture. An air-entraining agent is a liquid

chemical admixture used to create bubbles that will provide adequate freeze-
thaw protection in concrete by generating 5 to 7 percent of the volume with
air of properly sized and properly spaced bubbles. Air-entraining admixtures
are surfactants, soaps or detergents, primarily used to generate microscopic
size bubbles that render hardened concrete resistant to the effects of freezing
and thawing. It is also used to improve the workability/placeability of fresh
concrete.

61. Concrete admixtures.

a. Plasticisers.
(1). CERAPLAST 100:
i. Normal water reducing admixture
ii. Increased workability, density and strength without
increase in cement content
Cement savings without loss of workability or

27
 strengthrenders the concrete denser and stronger
Conforms to IS 9103-1999
(2). CERAPLAST 200:
i. Superior concrete water reducing admixture
ii. Increased workability, density and ultimate strength
without increase in cement content
iii. Impermeable and dense concrete Conforms to IS
9103 – 1999 and ASTM C 494 Type A

b. Superplasticisers.

(1). CERAPLAST 300: High range water reducing admixture.

i. Large reduction in water-cement ratio, high early

strength, early removal of formwork
ii. High quality concrete of lower permeability and
improved durability
iii. Ideal for producing pump- able concrete, placing
concrete in areas of congested reinforcement, marine /
coastal structures, especially in tidal zones Conforms
to IS 9103 – 1999 and ASTM C 494 Type F
c. Retarders.
 CERA RETARDER: Controlled set retarding admixture
i. Retards setting of concrete during delays between
mixing and pouring, prevents cold
joints
ii. Facilitates workability during high ambient
temperature
iii. Very ideal for use when concrete is to be transported
over long distances, useful for ready mixed concrete
industries Satisfies the stipulations of IS 9103 – 1999
and ASTM C 494 Type B and D
d. Retarding Superplasticisers:

28
  CERAPLAST 300 – RS: High range retarding super
i. plasticizer for flowing concrete
ii. Excellent workability at low dosages Retards setting
time
iii. Increased strength without increase in cement
iv. Excellent admixture for ready mixed concrete

e. Mortar Plasticizer.
 CERAPLAST LMP.
i. Liquid mortar plasticizers No mortar stiffening,
segregation or bleeding Less prone to drying shrinkage
cracks, increased adhesion, cost effective Accelerates
plastering and masonry works, improves the quality of
mortar, protects the mortar against bleeding and during
shrinkage

f. Integral Waterproofer.
 CERAPROOF IWP – POWDER: Waterproofing
admixture for mortar and concrete
i. Improves workability, produces dense and
homogeneous concrete, prevents corrosion of steel by
reducing capillaries
ii. Reduces water absorption of concrete and mortar
without causing strength reduction
iii. Used to produce impermeable concrete for water
retaining structures, terraces, basement , tunnel, piles,
plastering applications

g. Polymar Cement Modifier.

 CERAMICROSEAL: High performance co-polymer
based cement modifier

29
 i. Reduces shrinkage cracks, permeability and water
absorption
ii. Improves bond strength of mortar to porous
substrates like brick/old concrete
iii. Used wherever mass concrete is specified for below
grade construction such as basement, walls, floors,
foundations, swimming pools, retaining walls, storage tanks.

62. Chemical Composition. The major proportion of

commercial products is based on the following chemical materials, set out
in order of probable decreasing use.
a. Abiatic and pumeric acid salts.
b. Fatty Acid salts.
c. Alkyl - aryl sulphonates.
d. Alkyl sulphonates.
e. Phenol ethoxylates.

30