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Innovative Integration of RMC & PSC in Metro Construction
RMC
COEP TECHNOLOGICAL UNIVERSITY

A facility known as an RMC (Ready-Mix Concrete) plant produces concrete in a

factory or batching plant and then delivers it in a ready-to-use state to construction
sites. Several components, including cement, aggregates, water, and admixtures,
are combined in an RMC plant in exact amounts in accordance with a predetermined
recipe or mix design. In order to guarantee consistency and quality in the concrete
mix, computer-controlled machinery and equipment are usually used in the
production process at an RMC facility. After the concrete has been mixed, it is
delivered to building sites by trucks fitted with rotating drums, which keep the
concrete mixing and delay its setting time. Ready mix concrete is usually ordered in
units of cubic yards or meters. It must remain in motion until it is ready to be poured,
or the cement may begin to solidify.
RMC is a new concreting concept in the Indian Construction industry
introduced before one decade. It was initially not adopted by the contractors
because it is costly due to its large equipments and machineries and also due to
high tax on RMC and easy availability of manpower at cheaper rate but as time
elapsed they understood that in large or medium scale project it is cheaper as it
requires less time, less manpower and high strength as compared to Site mix
concrete*. So, ultimately it is time saving and cheaper. RMC is also eco-friendly as it
reduces the noise and air pollution because mixing is done in closed chamber as
compare to site mix concrete.
Constituents of RMC -
Inline Bins -
It refers to storage bins or compartments used to hold aggregates before they are
batched and mixed to produce concrete. These bins are an essential component of
the batching equipment within an RMC plant. Trucks carrying fine and coarse
aggregate can dump the material easily in it.
----------------------------------------------------------------------------------------------------------------
*Site mixed concrete – It is a volumetric concrete that is prepared at the construction
site.

Silo -
A silo in a Ready-Mix Concrete (RMC) plant is a storage structure used to hold bulk
materials, primarily cement, before they are used in the concrete mixing process.
Silos ensure a continuous supply of cement, protect it from moisture and
contamination, and are equipped with systems for controlled dispensing* to the
batching equipment. They play a crucial role in maintaining efficient and organized
storage, supporting uninterrupted concrete production in RMC plants.
Screw conveyor belt -

A screw conveyor belt is a mechanical device used to transport materials horizontally
or at a slight incline. It consists of a helical screw blade rotating within a tube or
trough, effectively pushing materials forward as the screw rotates.
Batching plant –
A batching plant in Ready-Mix Concrete (RMC) is a specialized facility where
ingredients such as cement, aggregates, water, and admixtures are accurately
measured and combined to produce concrete according to specific mix designs. The
plant ensures precise batching of materials, efficient mixing, and consistent quality
control to deliver ready-to-use concrete to construction sites.
----------------------------------------------------------------------------------------------------------------

*Dispensing- a machine or container able to release a product

Transit mixture –
A transit mixer, also known as a concrete mixer truck, is a specialized vehicle used
to transport freshly mixed concrete from the batching plant to construction sites. It
has a rotating drum mounted on the truck chassis, which continuously mixes the
concrete during transportation to maintain its homogeneity and workability. Transit
mixers are essential for delivering ready-to-use concrete efficiently and are
commonly seen on construction sites, facilitating the timely and convenient supply of
concrete to various project locations.
Concrete pumps –
A concrete pump is a machine used to transfer liquid concrete, typically from a
concrete mixer truck or batching plant, to the placement location on a construction
site. It operates by using hydraulic pressure to pump concrete through a system of
pipes and hoses. Concrete pumps are essential for placing concrete in hard-to-reach
or elevated areas, allowing for precise and efficient distribution of concrete during
construction projects.
Vibrators –
A vibrator is a mechanical device used to eliminate air voids and ensure proper
compaction of freshly poured concrete. It is typically inserted into the concrete during
the pouring process and vibrates at high frequencies to consolidate* the concrete
mixture, removing any trapped air bubbles and improving its strength and durability.
Vibrators are essential tools in concrete construction projects, ensuring uniformity
and quality in the finished concrete structures.
----------------------------------------------------------------------------------------------------------------

consolidate*- removal of water by compaction
A special type of RMC - UHPFRC-
UHPFRC stands for Ultra-High Performance Fiber-Reinforced Concrete. It's an

advanced type of concrete known for its exceptional strength, durability, and
resistance to various environmental conditions. UHPFRC contains high-strength
cement, fine and coarse aggregates, water, a high volume of fibers (such as steel,
glass, or synthetic fibers), and often chemical additives. It offers outstanding
mechanical properties, including high compressive and tensile strength, making it
suitable for demanding applications such as high-rise buildings, bridge decks, and
marine structures. UHPFRC is valued for its reduced maintenance needs, extended
service life, and enhanced sustainability compared to traditional concrete.
UHPFRC is a specialized formulation of concrete that typically includes the following

components:
1. Cement: UHPFRC uses high-strength cement, often with a high content of finely
ground materials such as Portland cement or a combination of Portland cement and
supplementary cementitious materials* (SCMs) like silica fume or fly ash*.
2. Fine Aggregates: Fine aggregates such as silica sand are commonly used in
UHPFRC to enhance workability and contribute to its dense microstructure. The
particle size and shape of the fine aggregates are carefully controlled to optimize the
properties of the concrete.
-------------------------------------------------------------------------------------------------------
Fly ash* - Fly ash is the fine powder formed from the mineral matter in coal,
consisting of the noncombustible matter in coal and a small amount of carbon that
remains from incomplete combustion.

Cementitious materials - They are any of the various building materials that may be
mixed with water (or other liquids) to form a plastic paste.
3. Coarse Aggregates: Coarse aggregates may be used in UHPFRC to provide bulk
and improve the packing density of the concrete mixture. The size and grading of
coarse aggregates are selected to achieve the desired mechanical properties of the
concrete.
4. Water: High-quality water free from contaminants is essential for mixing UHPFRC.
The water-cement ratio is typically kept low to minimize the porosity of the concrete
and enhance its strength and durability.
5. Fiber Reinforcement: UHPFRC contains a high volume of fibers to enhance its

tensile strength, toughness, and resistance to cracking. Fibers such as steel, glass,
or synthetic materials are commonly used in UHPFRC mixes to improve its structural
performance.
6. Chemical Additives: Various chemical additives may be incorporated into UHPFRC
mixes to enhance specific properties such as durability, shrinkage control, or
corrosion resistance. These additives may include corrosion inhibitors, shrinkage-
reducing agents, or water repellents.

Step wise working of an RMC -

1. Aggregate Handling:
Aggregates such as sand, gravel, and crushed stone are stored in designated storage bins or
silos at the RMC plant. These aggregates are typically sorted by size and type to meet the
specific requirements of different concrete mixes.
2. Cement Handling:
Cement is stored in silos at the RMC plant. The cement is typically delivered to the plant in
bulk via truck or rail and transferred to the storage silos using pneumatic or screw conveyors.
3. Water and Admixture Handling:
Water and admixtures (chemical additives used to modify the properties of concrete) are
stored in tanks or containers at the RMC plant. These materials are accurately measured and
controlled before being added to the concrete mix.
4. Batching:
Batching is the process of combining the required quantities of aggregates, cement, water,
and admixtures to produce a specific concrete mix. Batching may be done manually or using
computerized batching systems, depending on the size and complexity of the RMC plant.
5. Mixing:
The batched materials are transferred to a concrete mixer, where they are mixed together
thoroughly to form a homogenous concrete mixture. Mixing may occur in stationary mixers
or transit mixers, depending on the production capacity and transportation requirements of
the RMC plant.
6. Quality Control:
Quality control measures are implemented throughout the production process to ensure that
the concrete meets the required specifications and standards. Samples of the concrete mix

may be tested for strength, workability, and other properties to verify compliance with project
requirements.
7. Delivery:
Once the concrete has been mixed and quality control checks have been completed, it is
loaded into transit mixer trucks for delivery to construction sites. The transit mixer trucks are
equipped with rotating drums to keep the concrete agitated during transportation and prevent
it from setting prematurely.
8. Pouring and Placement:

At the construction site, the ready-mix concrete is discharged from the transit mixer trucks
and poured into forms or directly onto the desired locations. Concrete pumps or conveyors
may be used to transport the concrete to hard-to-reach areas or elevated locations.
9. Curing:
After placement, the concrete is allowed to cure and gain strength over time through
hydration reactions* between cement and water. Proper curing practices, such as keeping the
concrete moist and protecting it from extreme temperatures, are essential to ensure optimal
strength and durability of the finished structure.

----------------------------------------------------------------------------------------------------------------
Hydration reaction* - The hydration reaction primarily involves the hydration of various
compounds present in cement, particularly tricalcium silicate (C3S) and dicalcium silicate
(C2S), which are the main constituents of Portland cement.
Application of RMC –
1] RMC plants are commonly used in large-scale construction projects such as high-
rise buildings, stadiums, and shopping complexes. They provide a consistent and
high-quality supply of concrete, helping meet the demands of concrete volumes
required for these projects.
2] RMC plants cater to specialty projects that require specific concrete properties,
such as decorative finishes, high-strength concrete, or lightweight concrete.
Examples include architectural elements, sculptures, and specialized construction.

3] RMC plants play a role in emergency repair projects, supplying concrete for the
quick restoration of structures damaged by natural disasters, accidents, or other
unforeseen events.
Advantages of RMC are –
1. Time-Saving: RMC plants produce ready-to-use concrete that can be directly

transported to construction sites, eliminating the need for on-site batching, mixing,
and curing. This saves significant time and labor, leading to faster project completion
2. Cost-Effectiveness: Although the initial setup costs of an RMC plant may be higher
than traditional on-site mixing equipment, the efficiency and consistency of
production lead to cost savings in the long run. Reduced wastage, lower labor costs,
and improved project timelines contribute to overall cost-effectiveness.
3. Flexibility and Customization: RMC plants can produce a wide range of concrete
mixes tailored to specific project requirements, including variations in strength,
workability, and durability. Customization options allow for greater versatility in
meeting the needs of different construction applications
4. Reduced Site Congestion: With concrete production centralized at RMC plants,

construction sites experience reduced congestion from heavy machinery and
materials storage. This improves safety and efficiency on-site, particularly in
congested urban areas.
5. Quality Control: RMC plants use computer-controlled batching and mixing equipment
to ensure precise proportions of ingredients, resulting in consistent quality and
strength of the concrete mix. This helps in meeting project specifications and
standards reliably.
Disadvantages-

1] Quality Control Challenges: Despite rigorous quality control measures, issues

such as variations in raw materials, equipment malfunctions, or human error can still
occur in RMC plant operations.
2] Dependency on Transportation: RMC plants rely on a fleet of transit mixer trucks

to deliver the ready-mix concrete to construction sites. Transportation logistics,
including traffic congestion, road conditions, and distance from the plant to the
project site, can impact delivery schedules and increase costs.
3] Limited Shelf Life: Ready-mix concrete has a limited shelf life once it is mixed,
typically ranging from 1 to 2 hours depending on factors such as temperature,
humidity, and mix design. This can lead to waste if the concrete is not used promptly
or if there are delays in transportation.
Commercial setup of an RMC plant –

1. Market research and feasibility studies:
Conduct extensive market research to determine the need for RMC in your
target region. Evaluate competitors, discover potential clients, and analyze
market trends. Conduct a feasibility study to assess the practicality of
establishing an RMC facility in terms of expenses, possible revenue,
regulatory requirements, and so on.
2. Business Plan Development:
Create a complete business plan that includes your goals, target market,
marketing strategy, operational plan, financial predictions, and risk
management approach. Include information on the type and size of the RMC
plant you propose to establish.
3. Legal and Regulatory Compliance:

Obtain the appropriate permits and licenses for operating an RMC plant in
your jurisdiction. This may include environmental permissions, construction
permits, zoning permits, and so on. Adhere to local building laws, safety
regulations, and environmental norms.
4. Site Selection and Plant Setup:
Choose an appropriate location for your RMC plant based on aspects such as
proximity to construction sites, accessibility, raw material availability (cement,
aggregates, water), and logistical concerns.
Set up the plant's infrastructure, which includes the batching plant, storage
silos, water storage tanks, admixture storage facilities, and office space
5. Purchase of Equipment and Raw Materials:

Purchase high-quality equipment for batching, mixing, transporting, and
handling concrete. Create reliable supply chains for raw materials like
cement, aggregates, water, and admixtures.
6. Hire staff –

Hire experienced personnel, such as plant operators, technicians, drivers,

administrative staff, and sales/marketing professionals.
Train employees on safety protocols, equipment operation, quality control
procedures, and customer service
7. Quality Control and Assurance:

Implement stringent quality control procedures to ensure the consistency and
quality of the concrete produced. Regularly test raw materials, in-process
concrete, and finished products to ensure they meet industry standards and
customer specifications.
8. Marketing and Sales:

Create a marketing strategy to promote your RMC facility and attract
customers. This could include advertising, an online presence, attending
industry events, and developing relationships with construction companies,
contractors, and developers.
To gain a market advantage, offer competitive pricing, excellent customer
service, and on-time delivery.
9. Financial management
Tracking expenses, revenue, and cash flow helps you manage your finances
effectively. Secure enough funds for the initial setup costs, working capital,
and contingencies.
10. Operations Management:

Create effective operating procedures for batching, mixing, loading, and
delivering concrete. To maximize efficiency and reduce downtime, monitor
plant performance, equipment maintenance, and production schedules.

PSC – Pre- Stressed Concrete
PSC – Pre-Stressed Concrete
Pre-stressed concrete is a type of concrete where internal stresses are introduced to

improve its strength and performance. This is typically achieved by embedding high-
strength steel wires, strands, or bars (known as tendons) within the concrete before
it sets. Once the concrete hardens, these tendons are tensioned, creating
compression within the concrete. This compression counteracts the tensile forces
that occur when the concrete is subjected to loads, resulting in a stronger and more
durable material. Pre-stressed concrete is commonly used in construction for
bridges, buildings, parking structures, and other infrastructure projects where high
strength and long-term performance are required.
There are two types of pre-stressing concrete :-

1. Pre-Tensioned Concrete:
 In pre-tensioned concrete, the steel tendons are tensioned before the
concrete is poured.
 The tendons are usually laid out and tensioned between fixed supports known
as "beds" or "forms."
 Once the tendons are tensioned to the desired level, the concrete is poured
around them and allowed to harden.
 After the concrete has reached sufficient strength, the tendons are released
from their anchors, and the resulting compression from the tendons is
transferred to the concrete.
2. Post-Tensioned Concrete:
 In post-tensioned concrete, the steel tendons are tensioned after the concrete
has hardened and gained sufficient strength.
 Ducts or sleeves are embedded within the concrete during construction to
accommodate the tendons.
 Once the concrete has cured, the tendons are inserted into the ducts and
tensioned using hydraulic jacks.
 Anchors are then installed at the ends of the tendons to maintain the tension,
and the tendons are usually grouted to prevent corrosion and provide
additional bonding between the tendon and the concrete.

Applications of Pre-stressed Concrete:
1. Bridges: Pre-stressed concrete is widely used in the construction of long-

span bridges.
2. Buildings: It is employed in constructing floors, roofs, and other structural

elements.
3. Railway Sleepers: Pre-stressed concrete is used in the manufacture of

railway sleepers for enhanced performance.
Infrastructure:-

Mold Yard: Pre-stressed concrete elements are cast in molds. The mold yard
is where these molds are placed for casting. It should have a flat and level
surface to support the molds and should be large enough to accommodate
multiple molds simultaneously.
Pre-stressing Beds: These are specialized beds or tables where pre-stressed

concrete elements are cast. They are typically equipped with tensioning systems to
apply pre-stressing force to the concrete elements during casting.

Curing Facilities: Proper curing is crucial for the strength and durability of pre-
stressed concrete elements. Curing facilities may include curing chambers, curing
ponds, or steam curing systems, depending on the specific requirements of the
elements being produced.
Storage Area: There should be designated storage areas for raw materials such as
aggregates, cement, and steel reinforcement. Additionally, finished products should
have a storage area to await transportation.
Quality Control Laboratory: A quality control laboratory is necessary to perform

tests on raw materials, concrete mixes, and finished products to ensure compliance
with relevant standards and specifications.

Utilities: Adequate provision of utilities such as electricity, water, and compressed

air is essential for the operation of various equipment and processes in the plant.
Safety Equipment: Safety should be a top priority in any industrial facility. Safety
equipment such as fire suppression systems, first aid stations, emergency exits, and
personal protective equipment should be readily available throughout the plant.
Working Process:-
a. Material Preparation:-
Raw materials, including aggregates, cement, and tendons* or reinforcement, are
prepared and stored in designated areas.
b. Molding and Pre-stressing:-
The pre-stressing process involves tensioning tendons or reinforcement before pouring
concrete into molds.
c. Curing –
Pre-stressed elements are placed in curing chambers to allow the concrete to gain
strength and durability.
d. Cutting and Shaping:-
After curing, the pre-stressed elements are cut and shaped according to project
specifications.
e. Quality Control:-
Regular testing and quality control measures are implemented to ensure the pre-stressed
concrete elements meet required standards.
f. Storage and Transportation:-
Finished pre-stressed elements are stored and prepared for transportation to construction
sites.

-------------------------------------------------------------------------------------------------------------
Tendons * - it is a steel element such as a wire, cable, bar, rod, or strand used to
impart pre-stress to concrete when the element is tensioned.

Advantages -
Pre-stressed concrete offers several advantages over conventional reinforced

concrete, including:
1. Increased Strength: Pre-stressing introduces compressive stresses into the

concrete, which counteract the tensile stresses resulting from applied loads. This
results in a stronger and more resilient material, capable of supporting heavier loads
and longer spans.
2. Longer Spans: Pre-stressed concrete allows for the construction of longer spans
without the need for intermediate supports. This can result in more aesthetically
pleasing and efficient structural designs, particularly for bridges, viaducts*, and other
infrastructure projects.
3. Reduced Material Consumption: By optimizing the use of materials and
maximizing structural efficiency, pre-stressed concrete can lead to significant
reductions in the amount of concrete and steel required for construction, resulting in
cost savings and environmental benefits.
4. Flexibility in Design: Pre-stressed concrete offers greater flexibility in design,
allowing engineers to create innovative and complex structures with minimal material
usage. This versatility enables the construction of a wide range of architectural and
structural configurations to meet specific project requirements.
5. Improved Crack Control: Pre-stressed concrete typically experiences fewer and
narrower cracks compared to conventionally reinforced concrete, thanks to the
compressive stresses introduced by pre-stressing. This improves aesthetics and
reduces maintenance requirements over the lifespan of the structure.
Disadvantages-
While pre-stressed concrete offers many advantages, it also has some
disadvantages:
1. High Initial Cost: The upfront costs associated with pre-stressed concrete, including
materials, labor, and specialized equipment for pre-stressing, can be higher
compared to conventional reinforced concrete. This initial investment may deter
some project owners, particularly for smaller-scale projects.
2. Handling and Transportation Challenges- Pre-stressed concrete elements are
often large and delicate, requiring careful handling and transportation to avoid
damage during loading, unloading, and installation.
---------------------------------------------------------------------------------------------------------------
Viaducts* - a long bridge-like structure, typically a series of arches, carrying a road
or railway across a valley or other low ground .



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Innovative Integration of RMC & PSC in Metro Construction

COEP TECHNOLOGICAL UNIVERSITY

A facility known as an RMC (Ready-Mix Concrete) plant produces concrete in a

COEP TECHNOLOGICAL UNIVERSITY

Screw conveyor belt -

COEP TECHNOLOGICAL UNIVERSITY

*Dispensing- a machine or container able to release a product

COEP TECHNOLOGICAL UNIVERSITY

consolidate*- removal of water by compaction

A special type of RMC - UHPFRC-

UHPFRC stands for Ultra-High Performance Fiber-Reinforced Concrete. It's an

UHPFRC is a specialized formulation of concrete that typically includes the following

COEP TECHNOLOGICAL UNIVERSITY

5. Fiber Reinforcement: UHPFRC contains a high volume of fibers to enhance its

COEP TECHNOLOGICAL UNIVERSITY

Step wise working of an RMC -

COEP TECHNOLOGICAL UNIVERSITY

8. Pouring and Placement:

COEP TECHNOLOGICAL UNIVERSITY

COEP TECHNOLOGICAL UNIVERSITY

1. Time-Saving: RMC plants produce ready-to-use concrete that can be directly

4. Reduced Site Congestion: With concrete production centralized at RMC plants,

COEP TECHNOLOGICAL UNIVERSITY

1] Quality Control Challenges: Despite rigorous quality control measures, issues

2] Dependency on Transportation: RMC plants rely on a fleet of transit mixer trucks

Commercial setup of an RMC plant –

3. Legal and Regulatory Compliance:

5. Purchase of Equipment and Raw Materials:

COEP TECHNOLOGICAL UNIVERSITY

Hire experienced personnel, such as plant operators, technicians, drivers,

7. Quality Control and Assurance:

8. Marketing and Sales:

10. Operations Management:

COEP TECHNOLOGICAL UNIVERSITY

PSC – Pre- Stressed Concrete

PSC – Pre-Stressed Concrete

Pre-stressed concrete is a type of concrete where internal stresses are introduced to

There are two types of pre-stressing concrete :-

COEP TECHNOLOGICAL UNIVERSITY

COEP TECHNOLOGICAL UNIVERSITY

Applications of Pre-stressed Concrete:

1. Bridges: Pre-stressed concrete is widely used in the construction of long-

2. Buildings: It is employed in constructing floors, roofs, and other structural

3. Railway Sleepers: Pre-stressed concrete is used in the manufacture of

COEP TECHNOLOGICAL UNIVERSITY

Pre-stressing Beds: These are specialized beds or tables where pre-stressed

COEP TECHNOLOGICAL UNIVERSITY

Quality Control Laboratory: A quality control laboratory is necessary to perform

COEP TECHNOLOGICAL UNIVERSITY

Utilities: Adequate provision of utilities such as electricity, water, and compressed

COEP TECHNOLOGICAL UNIVERSITY

COEP TECHNOLOGICAL UNIVERSITY

Pre-stressed concrete offers several advantages over conventional reinforced

1. Increased Strength: Pre-stressing introduces compressive stresses into the

COEP TECHNOLOGICAL UNIVERSITY

COEP TECHNOLOGICAL UNIVERSITY

COEP TECHNOLOGICAL UNIVERSITY

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