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32nd Conference on OUR WORLD IN CONCRETE & STRUCTURES: 28 29 August 2007, Singapore
Abstract
Although the first RMC plant operated in India in 1987, the growth of RMC has picked
up only in the last decade. Most of the RMC plants are located in 7 large cities of
India, where they contribute 30% to 60% of total concrete used in these cities. RMC,
on all India basis contributes to about 5% of total concrete used. The growing
popularity of RMC in cities is for obvious reasons of constraints of construction space
and need to control environmental pollution. This is in spite of about 12% to 20%
higher cost as compared to site mixed concrete. The number of RMC plants in India,
are growing rapidly and being relatively new ones having most up-to-date machinery
and technology. The detailed information given in the paper is based on data collected
by 7 large offices of STUP Consultants P. Limited in India where they are actively
recommending the use of RMC in many major projects in all fields of Civil and
Engineering and Architectural applications in essence to obtain better quality of
work..
Keywords : Ready Mix Concrete, environmental pollution control, space constraints at site concreting
in large cities, India, growth of RMC.
Fig 1 : Subway at Pune picture of one of the entry ramps to the main subway
The first use of RMC took place in the city of Pune in 1987 but they did not have transit mixers and they
could not supply agitated concrete at the speed required for the Tanaji Wadi subway, which had a very
wide bottom slab and high retaining walls.
RMC could not be used by us and the RMC unit made efforts with others, but failed to satisfy and
closed down.
RMC has, however, grown modestly during the last decade. One of the main reasons for this lack of
growth of RMC in India lies in the construction practices followed in the country, which are traditionally
labour-intensive. Even today, a substantial proportion of concrete produced in the country is
volumetrically-batched and site-mixed, involving a large number of unskilled laborers in various
operations. The situation is however, slowly changing and a trend in favour of mechanization/semimechanization in construction is clearly discernible in the urban centers. It is therefore logical that most
of the RMC plants are concentrated in these centers.
RMC has helped in creating and boosting the demand for bulk cement. In fact, both are mutually
complimentary and nurturing RMC would go a long way in modernizing the construction sector.
Besides, both are today considered to be eco-friendly practices as they have the ability of minimizing
wastage of raw materials and reducing pollution.
On the other hand, being late starters, RMC producers in India have the advantage of adopting the
latest-generation plant and equipment, and many of the RMC facilities in India have state-of-the-art
plants, with sophisticated micro-processor based controls having ability of accurate weighing and
batching, automatic charging, adjustments for moisture compensation, inventory control, etc., besides
having a fleet of transit mixers of various capacities, most of these plants possess well equipped
facilities for pumping concrete.
RMC plants are situated in the suburbs of NOIDA and GURGAON and transit time is less than 1 hour
for concrete supplied within these suburbs. While for the main city, RMC is supplied mainly at night due
to day time traffic restrictions and the average transit time has become one and half to two hours, even
at night.
Our Delhi office considers that RMC is a success in Delhi, in spite of the extra cost compared to site
mixed concrete mainly because of space constraints at urban sites and also because of reliable quality,
speed and volume of supply of RMC.
At Ahmedabad the capital of the state of Gujarat
Fig 5 : Loading aggregate into a hopper which will feed it to a conveyor leading to a
mixing plant
90% of the concrete used is RMC for multi-storey commercial complexes and bridges due to shortage
of space for onsite Batching Plants.
The average transit time is 45 to 60 minutes, and can vary due to traffic problems by 30 to 60 minutes.
The rate of increase in demand is naturally slow and will increase only as per the quantum of supply
when the building industry resorts to RMC.
At Mumbai, Capital of the State of Maharashtra which is as large a metropolis as Delhi or Kolkata:
Fig 7 : A RCC Girder cast by RMC being erected at the Mithi River
Fig 10 : A Friction Slab being fed with concrete by a transit mixer in the background
Cost of RMC is 20% higher than that produced at site by mixing machines and 12% higher than that
produced at site by large Batching Plants. RMC is used in major infrastructure projects as well as
residential buildings and even in the construction of minor culverts
RMC is very successful at Bangalore, and the existing 34 RMC plants are unable to cope with the rising
demand.
Transit Mixers take 30 to 60 minutes to travel 15 km.
RMC is successful in spite of increased cost because they deliver fast and supply a reliable quality of
concrete.
RMC is more used when large scale concreting is involved and placement of 30 cu.m. per hour of
concreting maintaining high quality is possible. For smaller pours where a concrete pump is not
involved site produced concrete is preferred.
The other advantage of RMC is, that, of course, space and security for storage of large and fine
aggregates and cement at site are eliminated.
The reason why Bangalore is ahead of other Indian Cities, is the large volume of construction in the I.T.
Capital of India and therefore the excellent exposure of Business and Government with the world,
including a special attachment to Singapore.
At Chennai, capital of the State of Tamil Nadu.
The average transit time for transporting RMC from the plant to the site is 2 to 3 hours as the traffic is
less. RMC is a success in Chennai as quality can be ensured at the Batching Plant as well as reduced
involvement of labourers, in this busy city where there is a shortage of labourers. The increase in
demand of RMC beyond the estimated 1 million tons, is expected only if large individual residential
buildings resort to RMC.
At Kolkata, capital of the State of Bengal.