ITB-SOP-001 Ver.00 - Concrete Production

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WORK PROCEDURE Version: 00
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Title Concrete Production Prepared
05/09/2013
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CONCRETE PRODUCTION
Ettiene V. d. Merwe Signature ___________________ Date ___/___/___

(Laboratory Manager)
Prepared by:
Gabi G. Haddad Signature ___________________ Date ___/___/___
(Plant Manager)
Revised by: Diva Gondim Signature ___________________ Date ___/___/___

(Quality Assurance manager)
Ramzi Chidiac Signature ___________________ Date ___/___/___

(Deputy Managing Director)
Approved by:
Gabi Massoud Signature ___________________ Date ___/___/___
(Managing Director)
ITB-SOP-001 Ver. 00 ITB Nigeria Limited

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Table of Contents
1. PURPOSE 4
2. SCOPE 4
3. PROCEDURE DESCRIPTION 4
3.1 Materials Management 4
3.1.1. Supplier Management 4
3.1.2. Supplier and Materials Details 5
3.1.3. Raw Materials 6
3.1.3.1. Coarse Aggregates 6
3.1.3.2. Fine Aggregates 8
3.1.3.3. Cement 9
3.1.3.4. Water Source 11
3.1.3.5. Chemical Admixtures 13
3.1.4. Tests Reports 14
3.1.5. Conformance Monitoring 15
3.1.6. Materials Handling and Stockpile 15
3.2 Concrete Mixture Development and Selection 17
3.2.1. Concrete development (Mix Design) 17
3.2.2. Validation of Mix Design (Trial Mixes) 21
3.2.3. Tests Reports 23
3.2.4. Selection of Mix Design 23
3.2.5. Concrete Mixture Verification and Submittal 25
3.2.6. Control of Changes to Designated Concrete Mixtures 25
3.2.7. Concrete Mix Summary 25
3.3 Concrete Production 25
3.3.1. Production Planning 26
3.3.2. Concrete Production 26
3.3.3. Production Enviroment 27
3.3.4. Control of Plant Operations 28
3.3.4.1. Materials Receiving 28
3.3.4.2. Materials Storage and Handling 28
3.3.4.3. Weighing and Batching 28
3.3.4.4. Mixer and mixer controls 29
3.4 Concrete Testing 29

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3.4.1. Concrete Tests Frequency 29

3.4.2. Batching of Fresh Concrete 30
3.5 Concrete Delivery and Site Control 31
3.5.1. Transportation of Freshly Batched Concrete 31
3.5.2. Testing Hardened Concrete 35
3.5.3. Identification and Traceability 36
3.6 On Site Curing of Hardened Concrete 36
3.7 Concrete Troubleshooting 36
3.8 Measurement, Analysis and Improvement 37
3.9 Record Control 37
4. RESPONSABILITIES 38
5. CHANGE HISTORY 39
6. REFERENCES 39
7. APPENDIX 41

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1. PURPOSE
This document describes how ITB will assure that ready mixed concrete is produced
with consistent quality and in compliance with quality standards appropriate for intended
use.
2. SCOPE
This document applies to all stages right from receipt of raw material to delivery of
concrete at site.
Material should satisfy the requirements for safety, structural performance, durability
and appearances of the finished structures taking into account the environment to which
it will be subjected.
3. PROCEDURE DESCRIPTION
.1 Materials Management
.1.1. Supplier Management
The quality of our ready mixed concrete is based, to a large extent, on the
component materials used in the manufacture of the concrete.
Component materials stored at our facilities include: cement, fine aggregates,
coarse aggregates and admixtures (liquids – super plasticizers and retarders & dry –
silica fume) and water.
Our component materials come from a number of different suppliers. We consider
our suppliers to be a critical part of our business and we work closely with each
supplier to enhance the quality of our products.
ITB selects suppliers based on a number of criteria, including:
 previous experience with the supplier;
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 component material availability;

 price;
 knowledge of the supplier’s quality assurance/quality control program;
 Approved Materials;
 delivery; and
 support services available.
New suppliers are selected based on their qualifications and/or experience.
Our requirements by component material include:
.1.2. Supplier and Materials Details
Q1 – South Energix
Coarse
Q2 - Rass
Aggregates
KLM
Fine
Media Next
Cement Dangote
Liquid Fosrock and Mapei

Admixtures
Dry
Not applicable for ITB Abuja

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.1.3. Raw Materials
.1.3.1. Coarse Aggregates
Coarse aggregates (specification from supplier)

Requirement Test Specification
Normal weight ASTM C 33
Specific gravity, Test results every 3 months or when there appears to be a
absorption, and change in the aggregate quality, including a new lift or location
petrographic within the quarry
Potential alkali-silica Test evaluation required
or alkalicarbonate
reactions
Visual check Test required prior to shipment of aggregates for exposed
surfaces, for general appearance against the approved sample
Gradation Daily test according to BS standards (sieve analysis)
Upon arrival of aggregates on site, the following activities are performed:
A) Sample collection:
Samples are taken from individual trucks, to ensure that the selected materials have the
same quality as the materials of the quarry and comply with the standards used on site.
Visual inspections on all equipment is performed as well as on the different aggregates
produced.
Sample being collected from trucks

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Samples are collected according to standards:

 Using the cone method;
 Using the riffing method.
B) Test
Samples of coarse aggregates are tested in accordance with TMH 1 Method and with
the SANS 1083: 2006:
 Sieve analysis.(TMH 1 B 4);
 ACV(TMH1 B 1);
 10% fact.(TMH 1 B 2);
 Flakiness index.(TMH 1 B 3);
 Determination of bulk density (TMH B 14);
 If deemed necessary, a chemical analysis is performed on the aggregate.
Tests are done in a reputable chemical laboratory. According to the results, quarries for
supply are selected.
Materials being prepared for sieve analysis Sieve analysis being performed
Flakiness and elongation equipment used in the lab

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C) Storage
On site the Coarse Aggregates are stockpiled in such a way as to prevent
contamination of different sizes mixing together. For this purpose, bins are constructed
with concrete flooring in such a way to allow rain water to flow freely away from the
stock pile. Alternatively, roofing is placed over the aggregates to protect them from rain.
.1.3.2. Fine Aggregates
Fine aggregates (specification from supplier)

Normal weight ASTM C 33
Specific gravity and Test performed on a monthly basis or when there appears to be
water absorption a change in the aggregate quality
Gradation and Tests are performed on a daily basis. Minimum of one (1) sieve
fineness modulus analysis for every 200 tons shipped, or a minimum of one test
per day for each product purchased
Deleterious Daily test are performed
substances and
organic impurities
Aggregate certification In compliance with ASTM or equivalent specifications
Upon arrival of aggregates on site, the following activities are performed:
A) Sample collection
Fine aggregates are sourced from the area in the same manner as for coarse
aggregates.
B) Test
Fine aggregates are tested in accordance with TMH1 and with the SANS 1083: 2006.
Tests carried out on fine aggregates are as follow:
 Sieve analysis. Including the determination of the fines Modules (TMH1 B 54, B
13);
 Sand equivalent (TMH1 B 19);
 Organic content (TMH B 6);
 Phosphate and sulfates content (TMH B 16 T);
 Relative density;
 Determination of bulk density.

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Fine aggregates are sieved in order to remove all unsuitable material such as rocks and
clay lumps.
C) Storage
A bin is constructed with concrete flooring as to let water flow freely from the fine
aggregate. The bin is placed in such a way as to prevent contamination of the
aggregates. Roofing is placed over the aggregates
.1.3.3. Cement
Cement (specification from supplier)

Ordinary Portland cement confirming to NIS 444 – 1:2003 CEMl
Type
42.5N EN 197-1:2000 CEMl 42.5N
Chemical properties
Soundness of Cement
Setting time (min) According to EN 197-1:2000 CEMl 42.5N
Compressive strength
(N/mm2) – 2, 7 and 28
days

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Upon arrival of cement on site, the following activities are performed:

From delivery tanks, samples are randomly taken and sent for analysis on a 2 monthly
basis. If a change in the cement powder is observed, another sample is sent for
analysis in the site laboratory.
B) Test
The following tests are performed on cement power of every tanker:
 Setting time using the Vicamatic testing apparatus;
 The soundness test for the cement powder.
Vicamatic testing Apparatus Soundness of cement apparatus
Cement shall comply with:

 SANS 50197-1:2000 Cement -1 Compositions, specification and conformity
criteria for common cement, as well as SABS 197-1:2000
 SANS 14913-2005: Cement extenders used in Nigeria is only Silica fume; this is
imported from reputable Companies and do comply with SANS 14913-2005.
C) Storage
The cement is storage in Silos which are erected according to the contract
specifications and as per the batching plant manufacturers’ specifications. That will
keep the cement powder away from humidity effect. These silos are inspected on a
regular basis for cracks and humidity.
The pipes going in and out of the silos are inspected on a daily basis.

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Silos for cement storage

.1.3.4. Water Source
Quality of water should be tested for solid contents. It should be free from injurious
amount of impurities like oils, acids, alkalis, salt, sugar etc.
Water source (specification from supplier)

Solids content Test must be performed
Impurity test free from injurious amount of impurities like oils, acids, alkalis,
salt, sugar etc
Water source shall comply with:

 BS EN 1008: 2002.
Water is sampled and sent to a reputable laboratory to perform the following tests:
B) Tests
 Determination of phosphates and sulfates in the water;
 Determination of hardness of water;
 Determination of sugars in the water;

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 Culler;
 Test for solids in water.
If water is found to contain any of the above in a quantity not conforming to the
criteria as set out in BS EN 1008: 2002, a new source is found and re-tested. If
water is found to be satisfactory, it will then be used in the mix. Water of the same
quality is used in the mix designs.
C) Storage
Water is stored in concrete tanks or steel tanks, underground in order to have the
water at a temperature of less than 25◦C. however, if this is not possible, a tank
above ground is installed and covered, with sufficient air movement around it as to
help with the cooling of the water. If steel tank is used, it shall be visually inspected
on a regular basis to make sure it is not getting rusted or worn out.
Typical water storage tank

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.1.3.5. Chemical Admixtures
Chemical Admixtures (specification from supplier)

Super Plasticizers and retarders (wet)
Color (visual Control) Brown
Density according to 1.225 ± 0.03 at +20 ºC
ISO 758 (g/cm3)
Dry content according 37.3 – 39.7
to ISO 4316 (%)
pH according to EN 6.5 – 10.5
480-8
Silica fume (dry)
Residue by oven Results according to ASTM C494/C494M -13
drying
Types of admixtures are selected according to the contract demand, such as super
plasticizers and Retarders.
Chemical Admixtures shall comply with:

 ASTM C494/C494M -13. Standard specifications for Chemical Admixtures for
concrete;
 BS EN 934-1:2008 - Admixtures for concrete, mortar and grout - Common
requirements;
 BS EN 934-2:2009+A1:2012 - Admixtures for concrete, mortar and grout
Concrete admixtures. Definitions, requirements, conformity, marking and
labeling.
Upon arrival of chemical admixture on site, the following activities are performed:
Samples are collected in random fashion from selected drums or bins.
B) Test

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Tests are performed on the chemical additives to determine:

 Solids in the mix;
 Relative density thereof;
 Trial mixes are performed using a mix design in use, to confirm the soundness of
the chemical and the compatibility with the cement powders and cement
stretchers in use.
Trials are carried out according to TMH1 (D1,D3 and D5) and to SABS, to regulate the
quality of the chemicals received.
C) Storage
All chemicals are stored in a cool area. And well aired. Excessive quantities are not
procured to prevent the aging of admixtures.
Standard way of receiving and storing of admixtures*
* Note: the marking on the drums is in accordance with ASTMC 494/494M.
.1.4. Tests Reports
The tests are reported in the following documents:

 ITB-FORM-001 – Test on Aggregates;
 ITB-FORM-003 – Aggregate Crushing Value;
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 ITB-FORM-004 – Test on Cement Powers;

 ITB-FORM-005 – Water Absorption;
 ITB-FORM-006 – Determination of Bulk Density;
 ITB-FORM-007 – Chloride Test report;
 ITB-FORM-008 – Sulfate and Phosphate Test Report;
 ITB-FORM-009 – Relative Density;
 ITB-FORM-010 – Hollow Block Test Report;
 ITB-FORM-011 – Flakiness Index.
.1.5. Conformance Monitoring
At ITB receiving and conformance testing are routine quality assurance/quality

control functions. Through verification testing we monitor the quality of the products
we receive and verify the creditability of the reports provided by our suppliers.
Aggregate gradations are reviewed for consistency and conformance to grading
requirements. Control charts for representative sieves are prepared for analysis by
our Laboratory Technicians. Additional aggregate tests are provided and evaluated
as required.
Cement Mill Tests Reports are reviewed for changes from the previous reports and
for:
 ASTM C 109 cube strength;
 Setting time
 Fineness;
 Compound composition;
 Loss on ignition (LOI);
 Total alkali, expressed as Na2O equivalent.
.1.6. Materials Handling and Stockpile
ITB plants are served by truck. The Plant Manager and yard personnel at each plant
have awareness in materials management. All drivers delivering component
materials to our plants receive instructions regarding the yard layout, traffic flow,
speed limit, personal protective gear, and materials discharge or placement.
Aggregate ground storage areas are contained on three (3) sides. The fill pipes for
overhead cement and cement supplement silos are labeled for the respective silo.
ITB uses the following Table for submittals to summarize a Plant’s Material
Handling:

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Aggregates Proper unloading aggregate such as to prevent harmful segregation

and breakage
Proper building stockpiles or other storage methods such as to
prevent harmful segregation and breakage
Stockpiles or other storage located to prevent contamination;
arranged to assure that each aggregate as removed from its
stockpile or other storage is distinct and not intermingled with
others.
Interplant handling and transportation such as to prevent harmful
segregation.
Separate storage bins or compartments for each size and type of
aggregate properly constructed and charged to prevent mixing of
different sizes or types
Cementitious Bins or silos tight and provide for free movement to discharge
Materials opening
Where storage is provided for different types of cement or
cementitious materials, different materials isolated to prevent
intermingling or contamination
At the site, cements are stored in silos designed according to
contract specifications and properly ventilated structures with
adequate provision to prevent absorption of moisture
In case of cements of different types and from different sources are
kept in clearly marked separate storage facilities
These silos are inspected on a regular basis for cracks and humidity
The pipes from and to the silos are inspected on a daily basis
Admixtures For plants in areas with hot weather conditions, storage and
handling system for liquid admixtures sufficiently protected to
prevent heating of admixtures at any time. (Heating can cause
ingredients of some liquid admixtures to separate and, therefore,
affect concrete quality control)
Admixtures protected to prevent damage from contamination
Agitation provided for liquid admixtures that are not stable solutions

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Water Adequate supply, with pressures sufficiently constant or regulated to

prevent interference with accuracy of measurement
Water is stored in concrete tanks or steel tanks
Underground storage is used to have the water at a temperature of
less than 25 ºC, where possible a chilling plant is erected
If underground storage is not possible, a tank is installed at level
above the ground
Steel tanks are inspected on a regular basis
.2 Concrete Mixture Development and Selection
The design of a new concrete mixture and the selection of the proper mixture
proportions for a project or application is a critical aspect of our quality initiative. The
quality of our ready mixed concrete is a function of the properties of the individual
component materials as well as a function of the interaction of those selected
materials in the composite mix. We defined our methodology for selecting material
sources and our testing requirements for those materials. ITB does not use any new
materials in concrete until all initial testing is complete and the results have been
analyzed.
The initial requirement for designing or selecting the proper concrete mix proportions
is to determine the performance characteristics of the ready mixed concrete.
Performance characteristics for concrete may include, but are not limited to:
 Setting Characteristics
 Material compatibility evaluation
 Workability;
 Placeability;
 Strength;
 Uniformity;
 Durability; and
 Aesthetics.

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.2.1. Concrete development (Mix Design)
Mix designs are done using Table 11.2 and 11.5 (Fulton) for the determination of
water demand for fine aggregate and for the determination of the value of K for
coarse aggregates. Cement quantity and water content (W/C) are determined
according to the Manufacturers’ recommendations and experience with the cement
power as well as from the specific contract specifications.
Water reducing admixture is added according to manufactures recommendations for
the specific admixture.
Retarders are selected in similar fashion as for water reducing additives.
Getting the manufacturer of the admixtures involved in the design of the mix is a
priority for us as a company, so that we get the correct admixture for the specific
mix.
Cement stretchers are determined based on contract specifications.
Performance criteria for each project proposed concrete mixture is established by a
process of testing for the required performance criteria in the specification and
additional items needed by the contractor. Some of these include:
 Concrete strength data from previous job test records evaluated per ACI 214;
 Required average strength for each class of concrete established based on past
test records as per ACI 318 and ACI 301 for the specified strength in the project
specifications;
 Trial mixture evaluation either by the producer or Independent Testing
Laboratory;
 Develop mixtures at varying levels of w/cm and cementitious content and
composition;
 Process of further optimizing of mixture proportions for economy for prescriptive
and performance requirements;
 Mixture evaluation for setting characteristics and slump retention at extreme
temperatures;
 Effects of varying admixture dosages on plastic concrete properties.

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Fulton table 11.2 for the determination of water demand

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Fulton table 11.5 for the determination of the value of K for coarse aggregates

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Sample of mix design
.2.2. Validation of Mix Design (Trial Mixes)
As a conclusion, all mixes are made in the laboratory according to TMH 1 and to SABS. A
set of 18 cubes is made for every trial according to table below:
Time Number of cubes
24 hours 01
03 days 03
07 days 03
14 days 03
21 days 03
28 days 03
- 02 cubes for durability or permeability tests
Total 18

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Trial mix being made with the cubes for testing
Air Intrapmint meter scale
According to the results of trials, adjustments are made to the mix, and new trials are carried
out. There after Industrial trials are performed to get conformation that the mix is performing
as well in the field. These results are then forwarded to the Consultant for approval before
any concrete production.

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Coursing bath for the trials mixes being kept at 25 ± 2ºC
.2.3. Tests Reports
The tests are reported in the following document:

 ITB-FORM-002 – Compression Test
.2.4. Selection of Mix Design
The performance of new concrete mix designs is based on the trial mixtures we
prepare with the same materials that are to be used in the ready mixed concrete for
the project or application. When we prepare trial mixes we often request the
assistance of our supplier partners. Mixtures developed in this manner are provided
a designation and all pertinent performance data is documented on spreadsheets.
On some projects of a critical nature we will validate laboratory trial batches in
production size batches.
Our established mixes are evaluated based on historical statistical data. Concrete
properties that are established based on historical statistical data provide us with a
lower level of risk of non-conformance. We identify specific concrete mixes from
specific plants that we track and monitor. At a minimum we normally track a 3000 psi
and a 4000 psi air entrained and non-air entrained 35MPa mix from each plant. For
comparison purposes we will track the same mix out of multiple plants, if possible.
For plant standard deviations we test the concrete before the ready mixed truck
leaves the yard. For field standard deviations we test the concrete on the jobsite and

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utilize test results from Independent Testing Laboratories. Concrete strength data is
evaluated in accordance with SATCC table 7205-4.
It is vital that our company understand the needs of our customers or potential
customers. Beyond reviewing the project specifications and drawings, we ensure
that the concrete mix design(s) selected for a project or application meets the
defined and undefined needs of our customer.
We require our Laboratory Personnel, sales, and/or production personnel to attend
Pre-Bid Conferences on major projects.
These processes help us identify all pertinent details to ensure that the mixture we
propose for the work satisfies the needs of the specification and that of the
contractor.
From these meetings we establish at a minimum:
 Point of sampling for acceptance tests;
 Identify unreasonable requirements in the specification that conflict with other
requirements and establish consensus in writing
 Ensure that there will be proper testing and inspection on the project with
qualified people
 Ensure that we are provided with all test reports in a timely manner so we can
react to potential problems early
 Identify the special needs of the contractor based on the placement and finishing
methods chosen for the project.
 Other items that are identified in the specification review include:
 Costs associated with unique test requirements;
 Specific types of production and batching systems;
 Special types of component materials or concrete;
 Record maintenance of batch weights and reporting requirements on delivery
tickets;
 Restrictions on concrete unloading times;
 Restrictions on type of water or jobsite water addition;
 Rate of concrete delivery;
 Limits on concrete temperature;
 No chute/truck rinsing permitted on site;
 Safety training prior to going on site; and
 Back-up plant facilities.

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.2.5. Concrete Mixture Verification and Submittal
Most major projects require significant submittal information. Project Manager is

responsible for verifying that the proposed concrete mixtures we select for a project
or application conform to the requirements specified.
Submittal documentation includes material certification of all component materials,
designation of proposed mixtures and accompanying historical and evaluated test
data for the proposed mixtures.
.2.6. Control of Changes to Designated Concrete Mixtures
The Laboratory Manager is the only individual in our organization that is authorized
to make changes in designated concrete mixtures (other than minor moisture and
admixture adjustments). To minimize the potential for batching errors, changes to
designated concrete mixtures are always communicated in writing. When a mix is
changed, every employee assigned a mix book receives a revised page reflecting
the change.
.2.7. Concrete Mix Summary
Once we have selected the mixture component materials, developed the mixture
proportions, tested the mixture, and evaluated the results, a unique mix number is
assigned to the mixture.
Once a “Notice to Proceed” is issued for a project, our Laboratory Manager is
responsible for providing a list of mixes (including slump and air tolerances) to the
appropriate production, quality assurance, and administrative personnel.
.3 Concrete Production
ITB has the processes in place to monitor and control the production of our ready
mixed concrete. Facilities, Plant(s), and Equipment we use for the production and
control of our concrete are well maintained. The component materials for the
production of our concrete are received, tested, and stored (stockpiled) in accordance
with the procedures described in Section 3.2 Materials Management.

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.3.1. Production Planning
Production planning is an on-going activity. Prior to each production day, we develop

a plan for the allocation of resources. Component material inventories are reviewed
and material deliveries are scheduled. Special material requirements for unique
applications may require us to place orders months in advance.
Each evening our drivers are instructed of the time to report to work the following
day.
Drivers’ hours are regularly monitored during the work week to avoid fatigue and to
insure that we operate in compliance with all applicable regulations.
Scheduled maintenance of our ready mixed concrete trucks and plant equipment is
anticipated to minimize the impact on our production. Preventive maintenance is a
critical function of our plant operations. Ready mixed concrete trucks are washed,
fueled, and checked at the end of each day (pre-trip inspection) and are ready to go,
after a quick walk-around, the first thing each morning.
Daily planning is normally coordinated between production, dispatch and Laboratory
personnel and communicated to the respective individuals through dispatch.
Preliminary planning includes assigning Laboratory personnel, plant and/or project
responsibilities prior to the day of production. Production planning continues
throughout each day since change is inevitable.
.3.2. Concrete Production
Prior to batching the first load of concrete each day, component materials are loaded
into the plant; trucks are positioned for loading; and instructions are communicated
to the concrete batch personnel. Once a day the Plant Manager, or delegate,
performs a walk through inspection of the concrete plant.
Delivery tickets electronically communicate orders to the batch computer.
Once the batch instructions are received, the batch operator instructs the designated
truck to pull into the hole (under the plant for loading). Once the truck is properly
positioned for loading, the batch operator initiates the computerized loading process
of component materials into the central mixer or mixer truck receiving hopper and
the:
 aggregates are weighed and conveyed;
 cement and supplementary cementitious materials are gravity fed or transferred
by screw conveyor into the weigh batcher and subsequently discharged;
 water is weighed and discharged ; and
 concrete admixtures are introduced.
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The component materials batching sequence is optimized, based on experience, to

ensure batch uniformity following mixing. All of our major plants are equipped with
batch computers and our batch and dispatch software programs are integrated.
During the loading process, the driver remains with the truck and fills the truck
mounted water tank (if necessary). Once the truck is loaded, the delivery ticket is
forwarded to the driver. Special requests are highlighted on the ticket and the driver
reviews the directions. If additional items (expansion material, curing compound,
etc.) are to be delivered to the jobsite, the driver will receive a verbal confirmation of
the request from dispatch.
Once the driver understands the directions and has collected any additional items
necessary, the truck proceeds to the designated slump rack. The concrete is mixed
(at dry batch plants), the truck is rinsed and the concrete slump and consistency are
observed. Minor adjustments to the concrete may be made by qualified drivers and
significant adjustments require Laboratory personnel. Drivers are required to install
chute or rock guards prior to leaving the yard.
.3.3. Production Enviroment
The environment that we operate in can have a significant impact on the quality of
our ready mixed concrete.
During extreme conditions, we utilize hot weather concrete practices. The
temperatures which necessitate hot weather concrete practices may vary based on
specification requirements.
Our procedures for hot weather (ACI 305) concreting may include, but are not limited
to:
 Loader operators are instructed in areas of materials management.
 Overhead storage bins for aggregates are emptied at the end of each day.
 Coarse aggregate stockpiles are continuously watered for cooling (aggregate
moisture contents are verified regularly).
 Delays in the ordering and delivery of concrete are minimized. All concrete is
placed within 1 hour of the time the concrete was batched. Unless otherwise the
mix was modified using retarder
 Random loads have temperatures checked throughout the day.
 Various admixtures are used to avoid early setting of the concrete. Determination
of the proper admixture and appropriate dosage rate is determined by the
Laboratory Manager or qualified designated delegate.

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 Re-tempered concrete is not used. During the placement of the concrete, if the
concrete becomes stiff and requires the addition of excessive water for
workability, it is disposed.
.3.4. Control of Plant Operations
.3.4.1. Materials Receiving
 Materials are checked for conformance with the bills of lading or delivery ticket;
 Stockpiles are visually inspected for contaminants, deleterious materials (clay
coal and lignite; off-color sand), woodsticks, excessive under/oversize coarse
aggregate.
.3.4.2. Materials Storage and Handling
As described in section 3.2.4.

.3.4.3. Weighing and Batching
Measuring Accuracy
 A weekly scale check is performed, including verifying zero and tare on the
scales.
 Measuring devices are monitored for compliance with the applicable tolerances.
Batching Accuracy
 Batching accuracy is monitored, specifically our automated units, at designated
intervals.
 Batching stations are provided with current mix information and invalid or
obsolete information is promptly removed.
 Batch plant personnel are provided with clear and unambiguous dosage
instructions for the various admixtures handled at the plant.
 Our plant operators and substitute operators are familiar with admixture
dispenser operation, including the significance of measuring units (whether
ounce units, or various cement weight equivalents for different dosage rates);
and of the dosage setting and metering devices of automatic systems.
Batching Procedures
 The sequence of charging materials into the mixer is standardized.
 Delivery tickets indicate all of the information required by ASTM C 94 and those
additional items requested by the customer.
 Our plant personnel are provided with guidelines on handling non-conforming
batches of concrete.

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.3.4.4. Mixer and mixer controls
Central Mixer
 The concrete mixing time is monitored to insure that the minimum mixing time is
observed.
 Our batch plant operators and substitute operators at our central mix plants are
familiar with the amp/slump meter readings.
Truck Mixers
 All ready mixed truck drivers are aware of the required amount of mixing and of
the standard mixing and agitating speeds.
All truck mixers are kept in such a working condition as to:
o Allow for Safe and easy loading of the mixer;
o Allow for the proper mixing of the concrete being transported;
o Allow for safe discharging on site.
 Loading of truck mixers at the plant shall be done in such a way as to prevent the
spillage of concrete outside the funnel of the truck. As well as preventing
unwanted water from the operation to enter the drum of the truck.
.4 Concrete Testing
.4.1. Concrete Tests Frequency
The accuracy and reliability of our (quality control) tests results, in representing the
concrete tested, is largely dependent upon the frequency of tests we perform. The
frequency of our quality control testing may be a function of many factors including,
but not limited to:
 Project requirements;
 Evaluation of testing by others;
 Component materials analysis;
 Mix consistency and performance;
 Plant standard deviation; and
 Weather considerations.
Slump and temperature tests shall be made at the time of placement at the option of
the inspector as often as is necessary for control checks. In addition, these tests
shall be made when specified and always when strength specimens are made.

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All sampling for tracked mixes is performed under the direction of our Laboratory
Department. At a minimum, we require that each of our tracked mixes be tested
weekly out of each of our operating plants. The mixes that we track are sampled at
the plant and on the jobsite for statistical analysis.
.4.2. Batching of Fresh Concrete
Before startup of batching, and on a daily basis, samples are taken for the
determination of hygroscopic moisture and free water in aggregates. This is then
given to the batching plant operator to enable him do the correction for the free
water in the mix. This test is done 3 to 4 times a day at different times and according
to the weather. If it is a wet day it is performed more frequently. Same applies for
very hot days. Once batching is complete for a specific truck, a slump test is
performed to determine the workability. This is done for every truck being batched. A
truck is not sent out to site if the slump does not comply with the specification for the
mix. If the slump is not as per the specifications, it is then corrected and tested. Sets
of 3 cubes are randomly taken from trucks for verification of the mixes. These
samples are tested in parallel with the samples taken on site, in order to record any
difference in the mix from batching plant to site.
Concrete being batched*

* Care is taken to avoid any contamination between bins in the batching plant, prior
to batching.

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.5 Concrete Delivery and Site Control
Our concrete delivery process begins when the ready mixed concrete truck leaves
our yard and ends when the truck returns to the plant or other designated facility. We
require that all of our ready mixed trucks be equipped with rock or chute guards;
drums rotate at agitation speed during travel; trucks may not stop for food or breaks
on the way to the jobsite and must seek permission from dispatch to stop on the way
back; and that any concrete spillage be reported immediately to dispatch.
.5.1. Transportation of Freshly Batched Concrete
Transit mixers
All transit mixers are kept in such a working condition as to:
 Allow for Safe and easy loading of the mixer;
 Allow for the proper mixing of the concrete being transported;
 Allow for safe discharging on site.
Loading of mixers
Loading of transit mixers at the bathing plant shall be done in such a way as to
prevent the spillage of concrete outside the funnel of the truck, as well as preventing
unwanted water from the operation to enter the drum of the truck. At loading, the
drum shall be in motion as this eases the loading process and helps with the mixing
action.
Transportation
After loading, the speed of the drum shall be lowered to avoid the buildup of heat in
the concrete, as a result of friction in the drum and of aggregates rubbing against
each other excessively. A speed of 1 rotation per minute is to be maintained during
transit to site. The drum is at no time stopped from rotating during transit. A mixer
shall not spend more than the necessary time on site as this has an influence on the
workability and quality of the mix.

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Typical transit mixer being used

Discharging of Concrete
Prior to discharging, the drum is brought up to the mixing speed and rotated for a
minimum of 2 to 3 minutes to get the mix homogenous and to eliminate any
segregation that may have taken place during long transits. Tree ways of
discharging is used: Direct, Pump and bucket. The mix is then discharged in a safe
and orderly manner to eliminate the unnecessary waste of concrete.

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Direct discharge into element
Mixer Maintenance
All mixers are washed after discharging to avoid the setting of the small partials of
mortar remaining in the drum. Inspection of the drum is done on a weekly basis and
any fault is referred.
On site prior to casting of concrete
Upon arrival of the concrete on site, slump test is performed and recorded as well as
the arrival time. When the casting of the truck is delayed the slump test is again
performed before casting commences. Temperature is taken and recorded. Sets of 9
cubes are taken as per the contract specifications. Two for 3 days, 3 for 7 days and
4 for 28 days. If so required by the specifications, a set of 12 cubes is made. This
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will then be 3 for 3 days 3 for 7 days and 6 for 28 days as to be able to do the
statistical analysis These cubes are then left on site to set for 24 hours, covered with
a suitable material to prevent moisture loss in the cube. The cubes are then
collected and transported in the molds to the laboratory. There the cubes molds are
dismantled. The cubes are then registered in a lab register and cured in a curing
bath according to SABS standards.

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Slump test being performed using method (D3) of TMH1 in accordance with SABS standards.
Cubes made on site method (D1) of TMH 1 in accordance with SABS standards.
.5.2. Testing Hardened Concrete
Compression test specimens for monitoring our ready mixed concrete quality control
are premolded with freshly mixed concrete and cured in accordance with Practice C
31. Cube specimens for strength tests are routinely made for 3, 7 and 28 day
breaks, with a minimum of 7 and 28 day breaks. Three-day test permit early
recognition of variable strengths. If required by the client 60 day cube is made.
Allegations of nonconforming hardened concrete are investigated by our Laboratory
technician in accordance with the procedures identified.

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.5.3. Identification and Traceability
The ready mixed concrete that we deliver to the jobsite is identifiable and traceable.
If we discover that a critical nonconforming mix component was used in batching our
concrete, it is important that we be able to locate concrete used at other locations or
projects with the same defective material. The delivery ticket identifies the plant and
time that our concrete was batched and the truck number of the truck delivering the
concrete. From this information, the batch tickets at the plant can be reviewed and
the component materials and proportions determined.
.6 On Site Curing of Hardened Concrete
Curing is done for hardened concrete directly after removing of shattering or setting
of slabs. This requirement is contract specific as different curing compounds are
used and different methods of curing are specified.
.7 Concrete Troubleshooting
The production of ready mixed concrete is a complex process involving the

proportioning, batching, and mixing of various component materials under constantly
changing conditions. In spite of our best efforts there will inevitably be a need for concrete
troubleshooting. In this case all nonconforming products must be evaluated and documented
following ITB’s procedure for nonconformance. In the other words:
 Identify the source of the non-conformity – customer complaint or internal;
 Investigate the cause and identify it to process, product, quality system; and
record the results of investigation;
 Determine necessary corrective action and subsequent action to eliminate the
cause for future non-conformities;
 Controls established to ensure corrective action is taken and documentation of its
effectiveness.

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.8 Measurement, Analysis and Improvement
In order to improve our operations we establish and measure key indicators of our
performance. Through the process of measuring key indicators throughout our
operations, monitoring those activities, and analyzing the results, we can:
 Evaluate our ready mixed concrete consistency;
 Improve our processes; and
 Evaluate the effectiveness of our Quality Management System.
.9 Record Control
Records shall be maintained, to demonstrate that the required effect and result of
tests, has been achieved.
Samples of the types of records maintained include, but are not limited to:
 Approved Concrete Mix Designs
 Project Specifications
 Batch records indicating actual batch weights
 Scale Calibration Records
 Plant Inspection Reports
 Truck Inspection Reports
 Personnel Certification
 Laboratory Accreditation
 Material Certifications
 Delivery Tickets
 Reports of QC Test Results
 Statistical data and control charts for the following QC data
 Fine aggregate grading
 Coarse aggregate grading
 Air content
 Slump
 Compressive strength
 Other tests required by specification

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The documents are retained for a minimum of 3 years and project specific records are
retained for a minimum of 5 years after the completion of the contract.
4. RESPONSABILITIES
Laboratory Manager
The Laboratory personnel are directly responsible to perform the following activities:
 Sampling and testing of concrete and concrete materials; plant and field control
of concrete production; evaluation of concrete performance; failure analysis and
prevention;
 Review of project specifications and selection of job mixtures;
 Preparation of concrete mix designs;
 Evaluation of concrete performance;
 Product optimization;
 Research and development testing;
 When required attend to Pre-Bid Conferences on major projects;
 Personnel training;
 Management of the designated concrete mixtures.
Plant Manager
 Materials management awareness;
 When required attend to Pre-Bid Conferences on major projects;
 Verifying that the proposed concrete mixtures selected for a project or application
is conform to the requirements specified;

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 Personnel training;
 Once a day the Plant Manager, or delegate, performs a walk through inspection
of the concrete plant.
Quality Assurance
 Ensure that this procedure is understood and followed for all ITB staff involved to
this document.
5. CHANGE HISTORY
Version Changes
00 New document
6. REFERENCES
 TMH1 B 1 – The determination of the aggregate crushing value (ACV);

 TMH 1 B 4 – The sieve analysis of aggregates, including the determination of the
material passing the 0,425 and 0,075mm sieves;
 TMH 1 B 2 – The determination of the 10% fines aggregate crushing value;
 TMH 1 B 3 - The determination of the Flakiness Index of a coarse aggregate;
 TMH B 13 – The determination of the fineness modulus of fine aggregates;
 TMH1 B 19 – The determination of the sand equivalent of aggregates;
 TMH B 6 – The determination of organic impurities in sand for concrete;
 TMH B 16 – The quantitative determination of the total water-soluble salts in soils
aggregates;
 TMH1 D1 – The making, curing and compressive strength determination of
concrete test cubes;
 TMH D3 – The determination of the slump of freshly mixed concrete;
 TMH D5 – The determination of the air content of concrete;
 ASTM C 33 / C33M - 13 Standard Specification for Concrete Aggregates;
 ASTM C330 / C330M - 09 Standard Specification for Lightweight Aggregates for
Structural Concrete;
 ASTM C150 / C150M - 12 Standard Specification for Portland Cement;
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 ASTM C1157 / C1157M - 11 Standard Performance Specification for Hydraulic

Cement;
 ASTM C-917 - 05(2011) Standard Test Method for Evaluation of Cement
Strength Uniformity From a Single Source;
 ASTM C494 / C494M - 13 Standard Specification for Chemical Admixtures for
Concrete;
 ASTM C260 / C260M - 10a Standard Specification for Air-Entraining Admixtures
for Concrete;
 ASTM C595 / C595M - 13 Standard Specification for Blended Hydraulic
Cements;
 ASTM C 109 - ASTM C109 / C109M - 12 Standard Test Method for Compressive
Strength of Hydraulic Cement Mortars (Using 2-in. or [50-mm] Cube Specimens;
 ASTM C 1077 - 13b Standard Practice for Agencies Testing Concrete and
Concrete Aggregates for Use in Construction and Criteria for Testing Agency
Evaluation;
 ASTM C 172 / C172M - 10 Standard Practice for Sampling Freshly Mixed
Concrete;
 ASTM C31 / C31M - 12 Standard Practice for Making and Curing Concrete Test
Specimens in the Field;
 ASTM C138 / C138M - 13 Standard Test Method for Density (Unit Weight), Yield,
and Air Content (Gravimetric) of Concrete;
 ASTM C173 / C173M - 12 Standard Test Method for Air Content of Freshly
Mixed Concrete by the Volumetric Method;
 ASTM C231 / C231M - 10 Standard Test Method for Air Content of Freshly
Mixed Concrete by the Pressure Method;
 ASTM C143 / C143M - 12 Standard Test Method for Slump of Hydraulic-Cement
Concrete;
 ASTM C1064 / C1064M - 12 Standard Test Method for Temperature of Freshly
Mixed Hydraulic-Cement Concrete;
 ASTM C94 / C94M - 13a Standard Specification for Ready-Mixed Concrete;
 SANS 1083:2006 - Aggregates from natural sources - Aggregates for concrete;
 SANS 1491-3:2005 - Portland cement extenders Part 3: Silica fume;
 SANS 50197-1:2000/EN 197-1:2000 - Cement Part 1: Composition,
specifications and conformity criteria for common cements;
 SABS (South African bureau of standards);
 BS EN 934-1:2008 - Admixtures for concrete, mortar and grout - Common
requirements;
 BS EN 934-2:2009+A1:2012 - Admixtures for concrete, mortar and grout
Concrete admixtures. Definitions, requirements, conformity, marking and
labelling

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 BS EN 1008:2002 - Mixing water for concrete. Specification for sampling, testing

and assessing the suitability of water, including water recovered from processes
in the concrete industry, as mixing water for concrete;
 ACI 214-77 - Recommended practice for evaluation of strength test results of
concrete;
 ACI 318-08 - Building Code Requirements for Structural Concrete and
Commentary;
 ACI 301-10 - Specifications for Structural Concrete;
 ACI 305.1-06 Specification for hot weather concreting.
7. APPENDIX
 Appendix I – Template of “Diffusion Matrix for ITB QC Plan on Raw Materials”.

Ref. ITB-SOP-001
Page 1 of 43
Title Concrete Production Prepared: 05/09/2013
Appendix I

ITB-SOP-001 Ver.00 - Concrete Production

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ITB-SOP-

Ettiene V. d. Merwe Signature ___________________ Date ___/___/___

Revised by: Diva Gondim Signature ___________________ Date ___/___/___

Ramzi Chidiac Signature ___________________ Date ___/___/___

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

3.4.1. Concrete Tests Frequency 29

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

.1.1. Supplier Management

 component material availability;

.1.2. Supplier and Materials Details

Liquid Fosrock and Mapei

Not applicable for ITB Abuja

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

.1.3. Raw Materials

.1.3.1. Coarse Aggregates

Coarse aggregates (specification from supplier)

Sample being collected from trucks

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Samples are collected according to standards:

Flakiness and elongation equipment used in the lab

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Fine aggregates (specification from supplier)

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Cement (specification from supplier)

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Upon arrival of cement on site, the following activities are performed:

Vicamatic testing Apparatus Soundness of cement apparatus

Cement shall comply with:

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Silos for cement storage

Water source (specification from supplier)

Water source shall comply with:

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Typical water storage tank

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

.1.3.5. Chemical Admixtures

Chemical Admixtures (specification from supplier)

Chemical Admixtures shall comply with:

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Tests are performed on the chemical additives to determine:

Standard way of receiving and storing of admixtures*

* Note: the marking on the drums is in accordance with ASTMC 494/494M.

.1.4. Tests Reports

The tests are reported in the following documents:

 ITB-FORM-004 – Test on Cement Powers;

.1.5. Conformance Monitoring

At ITB receiving and conformance testing are routine quality assurance/quality

.1.6. Materials Handling and Stockpile

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Aggregates Proper unloading aggregate such as to prevent harmful segregation

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Water Adequate supply, with pressures sufficiently constant or regulated to

.2 Concrete Mixture Development and Selection

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

.2.1. Concrete development (Mix Design)

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Fulton table 11.2 for the determination of water demand

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Sample of mix design

.2.2. Validation of Mix Design (Trial Mixes)

ITB-SOP-001 Ver. 00 ITB Nigeria Limited

Ettiene V. d. Merwe Signature _________________ Date _/_/_

Revised by: Diva Gondim Signature _________________ Date _/_/_

Ramzi Chidiac Signature _________________ Date _/_/_