1. 1.

BATCH PLANT MAINTENANCE

2. Maintenance PLAN of Concrete Batching Plant CCCC-LBG / DAD November 14
3. 2. REFERENCES • ACI 117 SPECIFICATION FOR TOLERANCES FOR CONCRETE CONSTRUCTION
AND MATERIALS • ACI 301 SPECIFICATIONS FOR STRUCTURAL CONCRETE • ACI 304R GUIDE
FOR MEASURING, MIXING, TRANSPORTING, AND PLACING CONCRETE • ACI 311.1R ACI
MANUAL OF CONCRETE INSPECTION • ACI 311.5R PLANT INSPECTION OF READY-MIXED
CONCRETE • ASTM C 94 STANDARD SPECIFICATION FOR READY-MIXED CONCRETE • EPA US
ENVIRONMENTAL PROTECTION AGENCY • NRMCA NATIONAL READY MIXED CONCRETE
ASSOCIATION CCCC-LBG / DAD November 14
4. 3. ACI 117 SPECIFICATION FOR TOLERANCES FOR CONCRETE CONSTRUCTION AND
MATERIALS 2.4a CEMENTITIOUS MATERIALS Concrete batching tolerances Less than 30% of scale
capacity –0 to +4% of the required mass 30% of scale capacity or greater ±1% of required mass 2.4b WATER
& ADMIXTURES Concrete batching tolerances Total water content (measured by weight or volume) ±3% of
the required amount Added water or ice, and free water on aggregates ±1% of the total water content
Admixtures ±3% of the required amount 2.4c AGGREGATES Concrete batching tolerances Individual
material batching ±2% of the required mass CCCC-LBG / DAD November 14
5. 4. ACI 117 SPECIFICATION FOR TOLERANCES FOR CONCRETE CONSTRUCTION AND
MATERIALS CCCC-LBG / DAD November 14
6. 5. ACI 117 SPECIFICATION FOR TOLERANCES FOR CONCRETE CONSTRUCTION AND
MATERIALS CCCC-LBG / DAD November 14
7. 6. ACI 117 SPECIFICATION FOR TOLERANCES FOR CONCRETE CONSTRUCTION AND
MATERIALS CCCC-LBG / DAD November 14
8. 7. ACI 117 SPECIFICATION FOR TOLERANCES FOR CONCRETE CONSTRUCTION AND
MATERIALS Supplementary Cementing Materials By Rafat Siddique, Mohammad Iqbal Khan CCCC-LBG /
DAD November 14
9. 8. ACI 301- SPECIFICATIONS FOR STRUCTURAL CONCRETE Art. 1.6.3.2.c Obtain production samples
of materials at plants or stockpiles during the course of the Work and test for compliance with Contract
Documents. Art. 13.1.2.1.h Plant quality control— Submit certification of precast concrete plants in
accordance with the Precast/ Prestressed Concrete Institute (PCI) Plant Certification program. Alternatively,
submit manufacturing procedures and a quality control and testing program to Architect/Engineer for review
and acceptance. Submit evidence of plant certification or documentation of manufacturing procedures and
quality control program. Art. 13.2.15.1 Specify if PCI plant certification and testing and inspection program is
not required. Documentation of certification of plant and personnel. CCCC-LBG / DAD November 14
10. 9. SUB 01 45 00-070 ITP CONCRETE PRODUCTION ITP-SUB-GEN-G-PAS- 05009_A-CCCC- LBG /
DAD November 14
11. 10. ACI 304R - GUIDE FOR MEASURING, MIXING, TRANSPORTING, AND PLACING CONCRETE •
3.5—Water and ice measurement • 3.5.1 Batching equipment: Equipment and methods used should be
capable of routine measurement within the 1% tolerance. All equipment for water measurement should
be designed for easy calibration so that accuracy can be quickly verified. • 3.5.2 Aggregate moisture
determination and compensation: Moisture meters should be recalibrated monthly or whenever the
slump of the concrete produced is inconsistent. • 4.9—Maintenance • Mixers should be properly
maintained to prevent mortar and dry material leakage. Inner mixer surfaces should be kept clean and
worn blades should be replaced. Mixers not meeting the performance tests referenced in Section 4.8
should be taken out of service until necessary maintenance and repair corrects their deficient
performance. CCCC-LBG / DAD November 14
12. 11. ACI 311.1R ACI MANUAL OF CONCRETE INSPECTION 7. BATCHING AND MIXING CCCC-LBG
/ DAD November 14
13. 12. ACI 311.5R PLANT INSPECTION OF READY-MIXED CONCRETE 1.3—Inspector duties 1.3.1 To
determine required inspections, the inspector should review and fully understand the project specifications,
plans, and other project documents. The inspector should observe that the facilities, scales, and truck mixers
meet the specified project requirements. The provisions of the following documents should normally be
incorporated in the project specification: ACI 301; ASTM C 94/C 94M; Plant qualification in accordance with
the (NRMCA) checklist for certification of ready-mixed concrete production facilities; and Local agency
specifications. 1.3.2 Inspectors should conduct activities in accordance with all safety policies, health
standards, and safe work practices in effect at the job site. 1.3.3 The inspector should verify proper storage of
all materials on a daily basis. All storage areas should be clean and free of contamination. Cementitious
materials should be stored in weatherproof silos or similar structures. Aggregate storage areas should provide
for separation and free draining of stockpiled materials. Storage areas should be equipped with water spray
systems for maintaining aggregates in a saturated condition. Means for protecting and preventing freezing of
 aggregates during winter production should also be provided. Admixture storage areas should be suitably
insulated. CCCC-LBG / DAD November 14
14. 13. ACI 311.5R PLANT INSPECTION OF READY-MIXED CONCRETE 1.3—Inspector duties 1.3.4 All
tests and inspections should be conducted at the frequencies required by the project specifications in a manner
that does not interfere unnecessarily with the manufacture and delivery of the concrete. 1.3.4 During the first
batch being shipped to the project under the inspector’s jurisdiction, the inspector should be present at the
batching console to verify that the specified type and amount of materials, conforming to the approved design
mixture proportions, are batched and delivered to the mixer. 1.3.4 If the operation is automated and recorded,
the inspector should make observations as often as possible, preferably on a continuous basis, but at least once
per hour. If the batching operation is manual, the inspector should be present at the batching console during all
batching. The inspector should verify that quantities of materials for each batch fall within the tolerances set
forth by the project specifications. CCCC-LBG / DAD November 14
15. 14. SECTION 34 90 08: • 2.4.3.1 Materials shall be measured by weighing, except as otherwise specified in
the Contract documents or where other methods are specifically authorized. The apparatus provided for
weighing the aggregates and cement shall be suitably designed and constructed for this purpose. • Each size of
aggregate and the cement shall be weighed separately. • The accuracy of all weighing devices shall be such
that successive quantities can be measured to within one percent of the desired amount. • Cement in standard
packages need not be weighed but bulk cement shall be weighed. The mixing water shall be measured by
volume or by weight (mass). The accuracy of measuring the water shall be within a range of error of not over
one percent. • All measuring devices shall be subject to approval and shall be tested, at the Contractor's
expense, when deemed necessary by the Contracting Officer. • 2.4.3.2 When volumetric measurements are
authorized for projects, the weight (mass) proportions shall be converted to equivalent volumetric proportions.
• In such cases, suitable allowance shall be made for variations in the moisture condition of the aggregates,
including the bulking effect in the fine aggregate. • When sacked cement is used, the quantities of aggregates
for each batch shall be exactly sufficient for one or more full sacks of cement and no batch requiring fractional
sacks of cement will be permitted. • 2.4.4.1 Batching: (c) Batching equipment and scales shall meet the
requirements for measurement and accuracy in ASTM C94 CCCC-LBG / DAD November 14
16. 15. ACI 311.5R PLANT INSPECTION OF READY-MIXED CONCRETE 1.3.5 The inspector should verify
that coarse- and fine aggregate gradation tests are being performed in accordance with ASTM C 136 and that
the results meet the project requirements. If deviation occurs, batch plant personnel and the client should be
notified immediately, or previously authorized action should be taken. 1.3.6 The inspector should verify that
aggregate moisture contents are properly determined in accordance with ASTM C 566, and that the batch
quantities of materials are adjusted to compensate for free moisture in the aggregates. If aggregate moisture
contents are being measured by rapid methods, daily correlation tests following ASTM C 566 should be
conducted. 1.3.7 The inspector should determine that the trucks are in good operating condition and not
loaded beyond their rated capacities for mixing and agitation. Trucks should also be inspected (safety
regulations regarding confined spaces should be followed, if applicable) for blade wear, build-up of concrete
on the blades, and for proper mixing speed as described in the NRMCA Quality Control Manual. Truck
mixers should be equipped with counters or similar means to enable verification of the number of revolutions
applied to the drum. 1.3.8 The inspector should verify that the scales and other measurement systems have
been properly calibrated within the time period specified by the project specifications or referenced
documents 1.3—Inspector duties CCCC-LBG / DAD November 14
17. 16. ACI 311.5R PLANT INSPECTION OF READY-MIXED CONCRETE 1.3—Inspector duties 1.3.9 The
capability of the production facility to produce concrete within the temperature limits of the project
specification should also be evaluated and verified. In hot weather, this generally requires a system for
spraying and cooling aggregates and a system for efficiently weighing and delivering crushed ice to the mixer
in the range of 40 to 100 lb per yd3 (18 to 45 kg per m3). 1.3.10 For each batch of concrete the inspector
should verify that the concrete plant is furnishing to the purchaser a delivery ticket conforming to ASTM C
94/C 94M. A place should be provided on the ticket to reflect the following information: • Name of the
concrete plant; • Serial number of the ticket; • Date; • Truck number; • Name of the purchaser; • Project
designation (name and location); • Class or designation of concrete; Amount of concrete batched; • Time
batched; • The amount of water withheld during batching, if any, and the admixtures that may be added at the
jobsite; and • Any additional information required by the purchaser or the project specification. CCCC-LBG /
DAD November 14
18. 17. ACI 311.5R PLANT INSPECTION OF READY-MIXED CONCRETE 1.4—Reports 1.4.1 The inspector
should sign the delivery ticket, issue an inspection report, or supply other evidence that the concrete batching
has been inspected. 1.4.2 The inspector should issue a daily inspection report showing all test results and
documenting observations made during the day. Deficiencies and to whom they were reported should be
clearly identified. The ACI Manual of Concrete Inspection (SP-2) contains guidance on reporting and samples
of reports. CCCC-LBG / DAD November 14
19. 18. ASTM C 94- STANDARD SPECIFICATION FOR READY-MIXED CONCRETE Art. 6 & 9 6.6 A
certified copy of all proportions as established in Options A, B, or C shall be on file at the batch plant. 9.3
Mixing water shall consist of water added to the batch. The added water shall be measured by weight or
volume to an accuracy of 1 % of the required total mixing water. 9.4 Liquid chemical admixtures shall be
batched by mass or volume. Admixtures measured by either mass or volume, shall be batched with an
accuracy of ±3 % of the total amount required. Art. 10 10.1 Means of control shall be provided so that, as the
quantity desired in the weighing hopper is approached, the material shall be shut off with precision. Weighing
hoppers shall be constructed so as to eliminate accumulations of tare materials and to discharge fully. 10.3
Scales shall be considered accurate when at least one static load test within each quarter of the scale capacity
can be shown to be within ±0.15 % of the total capacity of the scale or 0.4 % of the net applied load,
whichever is greater. NOTE 11—The batching accuracy limit of 0.3 % of scale capacity establishes a
reasonable minimum weighing tolerance limit that is independent of the quantity of material being weighed. It
generally governs for smaller batch quantities weighed in weigh batchers (scales). NOTE 13—The scale
accuracy limitations of the National Ready Mixed Concrete Association Plant Certification meet the
requirements of this specification. ASTM International: C685/C685M Standard Specification for Concrete
Made by Volumetric Batching and Continuous Mixing CCCC-LBG / DAD November 14
20. 19. VARIATION IN CONCRETE PERFORMANCE DUE TO BATCHING • The NRMCA Plant
Certification requires producers to verify scale accuracy at least once every six months and arrange for prompt
recalibration and correction if non-compliance is indicated or if the plant is moved or other maintenance
impacts the weighing systems. • NRMCA certification requires that volumetric measuring of volumetric
measuring devices for water and chemical admixtures should be checked for accuracy at least once every 6
months. • The batching accuracy requirements in the NRMCA Plant Certification program are as required in
ASTM C94 and stated in Table 1. • For weighed ingredients, accuracy of batching is determined by
comparison between the desired weight and the actual scale reading; for volumetric measurement of water and
admixtures, accuracy is determined by checking the discharged quantity relative to the target, either by weight
on a scale or by volume in an accurately calibrated container. Volumetric measurement is commonly used for
water and typically used for chemical admixtures. It is realized that on any single batch, at least one of the
ingredients may be out of tolerance, as discussed later. • For the NRMCA plant certification, inspectors are
advised to review several batch records and to determine that the plant complies with the batching accuracy by
reviewing the average of at least 10 batches of concrete. • Improving batching accuracy can help attain more
consistent performance for fresh concrete properties that is important to the contractor and to reduce variation
of compressive strength of concrete CCCC-LBG / DAD November 14
21. 20. RECOMMENDED PRACTICES FOR BATCHING AND MIXING SCC: • Always know and adjust for
moisture in aggregates. Moisture meters for sand are strongly recommended. When producing SCC, run a
moisture test on all aggregates within 1.5 hours of actual batching of SCC. If the plant does not have a
moisture meter, moisture should be tested throughout the day. At a minimum, determine aggregate moisture at
the beginning of the work day, mid morning, and mid afternoon. Also check moisture any time new material
is delivered to the plant. • Once the admixture dosage is established, it should not vary unless water demand of
the materials has changed. This could be due to changes in any of the components – aggregates, cement,
supplementary cementitious materials. • Run gradations on aggregates a minimum of once per week or
whenever the SCC mix appears to have changed. If gradations have changed, adjust mix proportions
accordingly. • Run a laboratory trial once per month, or whenever the mix appears to have changed, to expose
possible water demand changes. • If a central mixer is used, monitor the mixer amp meter as a measure of
moisture level and water demand. Confirm that your amp meter can distinguish between an empty mixer and a
highly flowable SCC mix. If not, install a higher quality digital meter (0.1 amp resolution). In the absence of
HRWR, identify an amperage reading that corresponds to a slump which produces good SCC upon later
addition of the SCC admixture. If the amp reading is too high, adjust with water. The amp reading should be
stable before adding the SCC admixture. Establish a second target for after the addition of the SCC admixture.
Adjust with admixture if the reading is too high. Changing amp readings are an important indicator of changes
in materials. • If using a truck mixer, occasionally confirm moisture control and water demand by measuring
the slump before SCC admixture addition. Changes in “zero-admixture” slump are an indication of changes in
sand moisture or water demand. The “zero-admixture” slump should be within ± 25 mm (1 in.) of the
predefined target. • Make sure the truck mixer is empty – as little as 5 L/m3 (1 gal/yd3) of water can make the
difference between success and failure. Reverse ALL water and material out of drum before backing under the
batch plant. It is critical to make this point clear to truck drivers. • Mix SLOWLY. Poly-carboxylates that are
designed to produce highly stable SCC develop workability more slowly than typical high range water
reducers. Fast mixing leads to poor reproducibility and can induce excess foaming, which is difficult to get rid
of after the fact. The concrete should have a folding motion, not a slapping motion. For truck mixers, 1⁄2
speed (8-10 rpm) is sufficient. • Do not deliver the concrete until the contractor or finisher is ready. Standing
trucks can cause an SCC pour to go very badly. • As a general rule, addition of 5 L/m3 (1 gal/yd3) of water to
 SCC can increase slump flow 50-75 mm (2-3 in.); while removing 5 L/m3 (1 gal/yd3) reduces slump flow 50-
75 mm (2-3 in.) • Air content can have an impact on slump flow. The direction and magnitude of this
relationship depends on the materials, mix design, and the amount of air. CCCC-LBG / DAD November 14
22. 21. EPA – US ENVIRONMENTAL PROTECTION AGENCY Air quality management The maximum level
of concentration of solid particles, at testing points determined in accordance with this policy, is a total mass
of 250 mg/m3 of residual gases after completion of the process and before amalgamation with air, smoke or
other gases. In the case of concrete batching plants, cement, sand and aggregates can produce dust which may
enter neighboring premises and adversely affect amenity value. The best way to avoid offsite problems is to
prevent the release of the dust through good design and management techniques. The provision of natural or
artificial wind barriers such as trees, fences and landforms may help control the emission of dust from the
plant. All concrete batching plant sites should demonstrate good maintenance practices, including regular
sweeping to prevent dust build-up. The prevailing wind direction should be considered to ensure that bunkers
and conveyors are sited in a leeward position to minimize the effects of the wind. Aggregate material should
be delivered in a damp condition, and water sprays or a dust suppression agent should be correctly applied to
reduce dust emissions and reduce water usage. Aggregate stored on site in stockpiles should be contained
within three-sided storage bunkers with windshields that project 0.5 meter above the bunker wall. Conveyors
must be designed and constructed to prevent fugitive dust emissions. This may include covering the conveyor
with a roof, installing side protection barriers and equipping the conveyor with spill trays, which direct
material to a collection point. Belt cleaning devices at the conveyor head may also assist to reduce spillage.
Mixer loading areas should be roofed and enclosed on either two (drive-through) or three sides. Water sprays
and/or dust curtain of suitable design, or an effective air extraction and filtration system, should be installed to
suppress dust generated during mixer truck loading. Weigh bins and hoppers should be enclosed on three
sides and roofed where a front-end loader is used. The roof should extend 2 meters in front of the bin. Any
raw material spills should be removed promptly by dry sweeping. Water should not be used in the process of
cleaning up spills except where the area drains to a wastewater collection point where washing down would be
preferable to generating dust by sweeping. An approved fabric filter incorporating a fabric-cleaning device
should be installed on each cement storage silo. Adequate access to the filters should be provided to allow for
regular inspection and maintenance. A pollution control equipment register (PCER) should be used to record,
on a weekly basis, the following: pressure drop visual conditions of exhaust material incidents of filter media
failure/replacement. Water management Potential pollutants in batching plant waste water and storm water
include cement, sand, aggregates, chemical admixtures, fuels and lubricants. The site should be designed and
constructed such that clean storm water, including roof run off, is diverted away from contaminated areas and
directed to the storm water discharge system. Underground storage tanks should be tested annually for
integrity. Contaminated storm water and process wastewater should be captured and recycled. Concrete
agitator bowls and chutes must never be washed out to the storm water system or roadways. Process
wastewater and contaminated storm water collected from the entire site should be diverted to a settling pond,
or series of ponds. In general a high standard of yard and equipment maintenance will considerably reduce the
potential for discharge of sediment to the wastewater collection and recycling system. Regular inspection and
maintenance of the system is necessary to avoid discharges of contaminated water from the site. These
inspections and maintenance should be recorded. Areas where spills of oils and chemicals may occur should
be equipped with easily accessible spill control kits to assist in prompt and effective spill control, according to
the EPA Guidelines, Bonding and spill management. Staff should be familiar with spill response and
notification procedures CCCC-LBG / DAD November 14
23. 22. CCCC-LBG / DAD November 14 NATIONAL READY MIXED CONCRETE ASSOCIATION
24. 23. NRMCA CERTIFICATION • NRMCA Personnel Certifications: • Certified Concrete Sales Professional
(CCSP) • Certified Sustainability Professional • Concrete Delivery Professional Certification • Concrete Field
Testing Technician Grade II • Concrete Green Building Certification • Concrete Sustainability Professional
Certification • Concrete Technologist Level 2 "Technical Short Course" • Concrete Technologist Level 3 •
Concrete Technologist Level 4 "Durability Course" • Effective RMC Supervisor Certification • Environmental
Professional Certification for the Ready Mixed Concrete Industry • Fleet Manager Certification • NRMCA
Plant Certifications: • Quality: Plant and Truck Certification • Quality Certification Program • Environmental
Stewardship: Green-Star Certification Program • Sustainability: Sustainable Concrete Plant Certification •
Plant Manager Certification • NRMCA Safety Certification (Online) • OSHA 10-Hour Safety Certification for
General Industry • Pervious Contractor Certification • Plant Manager Certification • Sales Manager
Ceritification • NRMCA Product Certifications: • NRMCA Certified Environmental Product Declaration
CCCC-LBG / DAD November 14
25. 24. RAW MATERIALS CHECK LIST FOR READYMIX CONCRETE PRODUCTION FACILITIES •
Cementitious Materials • .1 Bins or silos are tight and with free movement to discharge opening [ ] • .2
Separate storage is provided for different types of cementing materials to prevent contamination – common
bag houses should shake down into the least affected cementing material [ ] • .3 Intra-plant handling prevents
 contamination [ ] • .4 All cementitious feed pipes are marked and designated (e.g. GU, HS, Fly Ash, etc)[ ]
CCCC-LBG / DAD November 14
26. 25. RAW MATERIALS CHECK LIST FOR READYMIX CONCRETE PRODUCTION FACILITIES •
Aggregates • .1 Aggregates stockpiles are arranged to assure that each aggregate as removed is clean, distinct
and not intermingled with others • .2 Procedures for unloading and storing aggregates prevents harmful
segregation [ ] • .3 Intra-plant handling and transportation prevents harmful segregation [ ] • .4 Separate
storage bins or compartments for each size and type of aggregate are properly constructed and charged to
prevent mixing of different sizes and types [ ] CCCC-LBG / DAD November 14
27. 26. RAW MATERIALS CHECK LIST FOR READYMIX CONCRETE PRODUCTION FACILITIES •
Water • .1 Adequate supply with pressures sufficiently constant or regulated to prevent interference with
accuracy of measurement where flow meters are used to measure mixing water – the flow meter shall be
calibrated and documented at intervals of no more than six months [ ] • .2 The concrete producer must provide
certification that the water used meets the requirements of CSA A23.1 at all times. Water for concrete
production may be from one of the following sources: • Potable source (water is supplied by a
government/commercial agency) [ ] • Non-potable source (satisfactory history of strength and durability made
with the water has been demonstrated) [ ] • Water from concrete production operations [ ] CCCC-LBG / DAD
November 14
28. 27. RAW MATERIALS CHECK LIST FOR READYMIX CONCRETE PRODUCTION FACILITIES
Admixtures .1 Storage of liquid admixtures is provided to prevent damage by freezing or contamination 2
Agitation is provided for liquid admixtures that are not stable solutions [ ] .3 Each admixture shall be
measured and discharged separately [ ] CCCC-LBG / DAD November 14
29. 28. CHAPTER 4: Production Facilities 4.1 Compliance with Standards: Production facilities and delivery
vehicles conform to the requirements of ASTM C94. • For delivery vehicles provide statement on procedures
and frequency to evaluate blade wear and buildup in truck mixers. • Review statement by company on
frequency of verification of accuracy of scales and volumetric measuring devices. • Review records of one
scale verification record– load test data sheet required. QUALITY CERTIFICATION 4.2 Monitoring
Batching Accuracy: PROGRAM Provide description of: • Procedures used to identify and address out of-
tolerance batches. Indicate the specific individual with responsibility for monitoring batching accuracy. •
Describe corrective actions used for consistent out of tolerance situations. • Provide two batch records from
each plant within the last 3 months. Records should indicate target and actual quantities batched for
cementitious materials, aggregates, batch water and admixtures. Tolerance information should be included in
batch records. Procedures stated to monitor and to address out of tolerance batches • Review procedures used
to identify out-of-tolerance batches and decision process and responsibility for addressing these situations. •
Review corrective action. • Review 2 batch records from each plant in submission within the last 3 months.
CCCC-LBG / DAD November 14
30. 29. CHAPTER 4: Production Facilities 4.3 Control of Mixing Water. Procedures stated to control mixing
water to within the ASTM C94 tolerance of ±3% Review procedures used for control of mixing water to
include, but not limited to: • Frequency of verifying accuracy of plant water measuring devices, procedure
used and accuracy requirements. • Verifying accuracy of measuring devices (volumetric to 1.5%, scales as per
scale check) and frequency • Addressing mixer wash-water prior to batching. • Control of mixing water
addition at the slump rack. QUALITY CERTIFICATION PROGRAM • Verifying accuracy of water
measuring devices on truck water tanks – procedure and frequency (water meters accurate to ±2%, sight gages
accurate to ±1 gallon). • Process for trim water holdback and communicating limits of water addition to the
purchaser and procedures required by drivers at the jobsite Review sample of 1 delivery tickets from each
plant in the submission of delivered loads documenting the recording of jobsite water addition and signature
of purchaser. CCCC-LBG / DAD November 14
31. 30. PLANT CERTIFICATION GUIDANCE TO CONCRETE PRODUCERS SEEKING AND
MAINTAINING PLANT CERTIFICATION SCALE ACCURACY VERIFICATION Scale accuracy should
be verified anytime the plant is moved, maintenance activities on the plant impact the weighing systems, or
when there is a concern on scale accuracy determined from the batchman operating the batching process or the
quality of concrete. There are some differences in what the scale companies are accustomed to doing and what
is required by the NRMCA plant certification and ASTM C94. The following should be communicated with
the scale company before they do scale checks: • Minimum quantity of test weights should be at 10% of scale
capacity. Aggregate scale capacities will generally govern the minimum amount of test weights required –
about 4000 lbs is typically needed. (There may be situations where the plant configuration does not permit the
minimum test weights to be used and that has to be verified by the plant inspector). • Test weights should be
certified to be accurate to 0.01% of their indicated load within the last two years. This is typically not a
problem with commercial scale companies. • Scale checks should be done through range of use of the scales.
Scale companies may only verify it through 50% of the scale capacity. • Up through 50% of the scale
capacity, scale checks should be done using a build-up test load using a combination of product and test
 weights in a process called a substitute test. Scale increments should not be skipped. In substitute testing,
product in the scale should only be to the load previously verified – as close as possible. • Over 50% of the
scale capacity, strain test loading is permitted. An unknown quantity of product is charged and the incremental
weight indication with the test weights is verified. At least two points should be tested in this portion of the
scale – through typical range of use. • Scale accuracy requirements (ASTM C94) is the greater of • ±0.15% of
scale capacity (governs at the lower end) • ±0.4% of applied test load • If it's not accurate the scale has to be
adjusted. • A copy of the scale verification data sheets should be obtained to indicate details of the test loads
used, test load increments, load indications and load error. A certificate just indicating a scale is OK is not
acceptable. CCCC-LBG / DAD November 14
32. 31. GUIDANCE TO CONCRETE PRODUCERS SEEKING SCALE ACCURACY VERIFICATION •
Additional Information • a. Each scale is comprised of a suitable system of lever and/or load cells, which will
weigh consistently within the tolerance specified by the MRMCA, with loads indicated either by a beam with
a balance indicator or a full reading dial or digital readout display verifying accuracy. • b. Each scale must be
calibrated at a minimum of 2 points and at 20% and 80% of the scales normal operating capacity. • c. The
Scale Manufacturer or Scale Company must supply the necessary documentation that government approved
test weights are used, which are certified and traceable. PLANT CERTIFICATION AND MAINTAINING
PLANT CERTIFICATION • d. The Scale Manufacturer or Scale Company must provide a procedure or check
list which is used for the inspection and to document all mechanical checks, calibration test results and any
deficiencies in the scale or weighing system. • e. The Scale Manufacturer or Scale Company’s qualified
technician must sign the MRMCA Scale Check Data Form certifying that all requirements have been met. • f.
All scale check and calibration reports/records must be kept on site and must be available for inspection at all
times. CCCC-LBG / DAD November 14
33. 32. PLANT CERTIFICATION GUIDANCE TO CONCRETE PRODUCERS SEEKING AND
MAINTAINING PLANT CERTIFICATION WATER METER ACCURACY VERIFICATION Accuracy of
water meters should be verified at least once every six months. Maintain documentation of these verifications
for review by the inspector. Accuracy of water meters is the same as that required for batching accuracy
±1.5%. Measure accuracy using a large enough volume of water – at least 50 gallons. Methods include: •
Discharge water into a 55-gallon drum and weigh the quantity – can be suspended from the cement scale. •
Perform this at least 3 times to obtain an average. • Some discharge 200+ gallons into a truck mixer if truck
scales are available. After weighing the truck, water is discharged and the truck is weighed empty to
determine water in the drum. • Discharge water into a calibrated container of at least 50 gallon capacity.
Calibrations on the container should be accurate enough to measure to within the required accuracy tolerance.
When water is measured by weight, accuracy requirements for scales apply. COE CRD-C 143-62 Handbook
for Concrete and Cement Specifications For Meters For Automatic Indication Of Moisture ln Fine Aggregate
CCCC-LBG / DAD November 14
34. 33. PLANT CERTIFICATION GUIDANCE TO CONCRETE PRODUCERS SEEKING AND
MAINTAINING PLANT CERTIFICATION ADMIXTURE DISPENSER ACCURACY VERIFICATION
The batching accuracy of dispensers of liquid admixtures shall be checked at least every 6 months. This
dispenser accuracy check is usually performed by collecting the chemical admixture into a calibrated
container. It is acceptable to use a dispenser measuring unit as the calibrated container. The process for
checking accuracy using a calibrated dispenser measuring unit is as follows: • A dosage quantity check should
be performed for each dispenser. • Determine the target quantity based on a typical dosage rate within the
recommended dosage range. • Dose target quantity of admixture into the dispenser measuring unit and hold
for visual measurement. • Calculate and confirm accuracy. When the admixture is measured by a meter and
batched through a direct feed admixture system (with no dispenser measuring unit), the accuracy check is
conducted using a calibrated flask/container. The process for checking accuracy using graduated flask or
container: • A dosage quantity check should be performed for each dispenser. • Determine the target quantity
based on a typical dosage rate within the recommended dosage range, but usually limited to under 5 gallons. •
Dose target quantity of admixture into calibrated flask/container for measurement. • Calculate and confirm
accuracy. The company can perform their own dispenser accuracy checks instead of calling the dispenser
representatives. If the meter is not accurate, the admixture dispenser representatives should be called in to
calibrate the dispensing system. Documentation of admixture dispenser accuracy verification should be
retained for review by the inspector. Some producers collect admixture at the point of discharge into the mixer
to verify the accuracy of the dispensing system. This process checks the integrity of the lines through which
the admixture flows in addition to the dispenser accuracy. CCCC-LBG / DAD November 14
35. 34. PLANT CERTIFICATION GUIDANCE TO CONCRETE PRODUCERS SEEKING AND
MAINTAINING PLANT CERTIFICATION MOISTURE PROBE ACCURACY VERIFICATION Follow
manufacturer’s directions for verifying accuracy. • The accuracy of moisture probes should be relative to an
aggregate moisture measurement by drying out an aggregate sample on a hot plate or microwave oven (ASTM
C566). The aggregate sample tested should be obtained from as close to the location of the moisture probe
 measuring the aggregate moisture. • There is no stated accuracy (tolerance) for moisture probes in the
NRMCA Check List. Using the required accuracy (±1.5%) for water meters can be considered as a basis for
requiring corrections to the device (calibration). • Maintain documentation of these checks and provide for
review to the inspector. CCCC-LBG / DAD November 14
36. 35. SUMMARY ITEM Frequency Other Monitoring Batching Accuracy Review 2 batch records from each
plant in submission within the last 3 months. Review procedures used to identify out-of-tolerance batches and
decision process and responsibility for addressing these situations. Review corrective action. Control of
Mixing Water Review sample of 1 delivery tickets from each plant in the submission of delivered loads Scale
accuracy verification Anytime the plant is moved, maintenance activities on the plant impact the weighing
systems, or when there is a concern on scale accuracy determined from the batchman operating the batching
process or the quality of concrete Water meter accuracy verification & Water Flow Meter At least once every
six months. When water is measured by weight, accuracy requirements for scales apply. Admixture dispenser
accuracy verification Checked at least every 6 months Moisture Probe accuracy verification ACI 304.R/3.5.2
Aggregate moisture determination and compensation Moisture meters should be recalibrated monthly or
whenever the slump of the concrete produced is inconsistent. Followmanufacturer’s directions for verifying
accuracy All measuring devices shall be subject to approval and shall be tested, at the Contractor's expense,
when deemed necessary by the Contracting Officer. Section 34 90 08 Art. 2.4.3 consistency-recording meters,
such as those operating from the amperage Some draw on the electric motor drives for revolving-drum
mixers, have also proven to be useful. The most positive control method for maintaining batch-to- batch
uniformity, however, is a regularly scheduled program of tests of the fresh concrete, including unit weight, air
content, slump, and temperature. CCCC-LBG / DAD November 14
37. 36. CCCC-LBG / DAD November 14 PLANT MAINTENANCE PLAN
 37. PLANT MAINTENANCE PLAN DAILY
 1. Inspect oil and filter on air compressor and drain tank, manifolds, and all water traps.
 2. Inspect and fill all oilers on plant.
 3. Inspect all air cylinders.
 4. Inspect tension on all V-drive belts.
 5. Inspect conveyor belts for alignment and excessive wear.
 6. Perform housekeeping items, such as cleaning up dust and debris. First, the mechanism of lubricating oil
should be change often. Before work, the machine should have an empty running. Second, check whether
there is water in the bucket of ingredients; if you find some, clean it up
 . CCCC-LBG / DAD November 14
38. PLANT MAINTENANCE PLAN DIARIO
38. 1. Inspeccione el aceite y el filtro de aire del compresor y el tanque de drenaje, colectores, y todas las trampas
de agua.
39. 2. Inspeccione y rellene todos los engrasadores en planta.
40. 3. Inspeccione todas las botellas de aire.
41. 4. Inspeccione la tensión de todas las correas V-drive.
42. 5. Inspeccione las correas transportadoras para la alineación y el desgaste excesivo.
43. 6. Lleve a cabo los elementos de limpieza, tales como la limpieza de polvo y escombros. En primer lugar,
el mecanismo de aceite lubricante se debe cambiar con frecuencia. Antes del trabajo, la máquina debe
tener un funcionamiento vacía. En segundo lugar, comprobar si hay agua en el cubo de ingredientes; si
encuentra alguna, limpiarlo.

44. 39. PLANT MAINTENANCE PLAN Weekly

1. Lubricate all bearings (ONE PUMP ONLY). Included are head and tail pulleys on all conveyors, snubber roller on
loading conveyor, head and tail bearings on cement feeder screws, wheel bearing supports on turn head, etc.
2. Lubricate all aggregate gate pivot points.
3. Replace or blow clean all air filters on air compressor and aeration blowers.
4. Inspect and tighten all bolts and bearing set screws.
5. Inspect and/or adjust all belt wipers.
6. Lubricate packing at the bottom and top ends of the cement feeder screws with oil.
7. Inspect all bags in cement bag filters. Be very careful with the batching's control instrument, because this is an
electronic instrument, once exposed to the sun or rain or lightning, it will be damaged and seriously affect the
accuracy of the ingredients, which affect the progress. The batching's control instruments should be placed, by
erection, in a facility that will be sun proof, rainproof, dustproof and lightning protected.
40. PLANT MAINTENANCE PLAN Semanal
1. Lubrique todos los cojinetes (UNA BOMBA SOLAMENTE). Se incluyen en la cabeza y la cola poleas en todos los
transportadores de rodillos, cojinetes de carga amortiguador en transportadoras, cabeza y cola de tornillos
alimentadores de cemento, cojinete de la rueda apoya en la cabeza a su vez, etc.
 2. Lubrique todos los puntos de pivote puerta agregados.
3. Vuelva a colocar o golpe limpio todos los filtros de aire en el compresor de aire y sopladores de aireación.
4. Inspeccione y apriete todos los pernos y tornillos de fijación del rodamiento.
5. Inspeccione y / o ajustar todos los limpiadores de correa.
6. Lubricar embalaje en la parte inferior y los extremos superiores de los tornillos de alimentación de cemento con
aceite.
7. Inspeccione todas las bolsas en los filtros de bolsa de cemento. Tenga mucho cuidado con el instrumento de control
de la dosificación, ya que este es un instrumento electrónico, una vez que se expone al sol o la lluvia o los rayos, se
dañará y afecta seriamente la exactitud de los ingredientes, que afectan a los progresos. Instrumentos de control de la
dosificación deben ser colocados, por la erección, en una instalación que va a ser a prueba de sol, impermeable, a
prueba de polvo y relámpagos protegidos.
45. 41. PLANT MAINTENANCE PLAN Monthly
46. 1. Inspect oil level in all gear reducers.
47. 2. Adjust skirt boards as needed.
48. 3. Adjust and tighten conveyor belts as needed.
49. 4. Change oil in air compressor. CCCC-LBG / DAD November 14
50. 42. PLANT MAINTENANCE PLAN Mensualmente
51. 1. Revise el nivel de aceite en todos los engranajes reductores.
52. 2. Ajuste faldones, según sea necesario.
53. 3. Ajuste y apriete las cintas transportadoras, según sea necesario.
54. 4. Cambie el aceite del compresor de aire. CCCC-LBG / DAD November 14
55. 43. PLANT MAINTENANCE PLAN Semiannually 1. Change oil in all conveyor gear reducers. 2. Remove
bags in cement bag filters and blow clean. 3. Tighten or replace all V-belts as needed. 4. Inspect scale and
water meter accuracy. 5. Inspect hanger bearings in feeder screws and replace as needed. 6. Inspect and
acidize boiler. 7. Inspect and/or replace bin aeration pads CCCC-LBG / DAD November 14
56. 44. PLANT MAINTENANCE PLAN Semi-anualmente 1. Cambie el aceite en todos los reductores
transportadora. 2. Retire las bolsas de filtros de bolsa de cemento y golpe limpio. 3. Apriete o reemplace todas
las correas en V, según sea necesario. 4. Inspeccione la precisión de escala y agua metros. 5. Inspeccione los
cojinetes de la suspensión en los tornillos de alimentación y reemplace según sea necesario. 6. Inspeccione y
acidificar la caldera. 7. Inspectional y / o reemplazar las almohadillas del bin aireación CCCC-LBG / DAD
November 14
57. 45. CCCC-LBG / DAD November 14

Cement-320

I. E
II. E
III. E
E Cement-320

I. E
II. E
 III. E
IV. E
Cement-320

V. E
VI. E
VII. E
VIII. E
IX.

X. E
XI.