Japan International

Cooperation Agency

ICP for Batching plan ｔ　 (draft)

1. Facility of batching plant
2. Daily adjustment of concrete mix design
3. Compression test
4. Common mistakes in the field
5. Good practice in the field

7 August 2023
 1. Facility of batching plant
(1) Overview of batching plant

Cement silo

Storage bin
Conveyor belt

weighing
device

Mixer Aggregate stockyard

Conveyor belt
Additive
Aggregate pull-out gates
tank

Hopper

2
(2) Aggregate stock yards

Avoid mixing different aggregates, sun rays, and rainwater

Aggregate stock yard Aggregate stock silo

3
(3) Transfer of aggregate by conveyor belt

Aggregate stock silo Batching plant

el t
veyor b lt
C on or be
vey
Con

Conveyor belt
Aggregate pull-out gates

Aggregate pull-out Gate Conveyor belt 4

(4) Cement and additive stock silo
Blast furnace cement Portland cement I

Portland cement III

Delivery of cements Cement name labels at inlets

Tanks of additives Additives name labels at inlets 5

(5) Batching plant

t
or bel
onvey Mixer
C

Storage bin
Weighing
device

Mixer
Additive
tank

Weighing device Inlet to the storage bin Inside of the mixer 6

(6) Operation room and laboratory

Batching plant
Monitor TV

Operation room
Camera

Constant temperature curing water tank Compression test equipment

(20℃±2℃ ） 7
2. Daily adjustment of concrete mix design

Surface water rate of aggregates

 Measure the surface water rate of fine aggregate of stock yard every day
 If it is raining or aggregate is dry, water rate shall be adjusted based on the
measurement
 Adjust the water volumes based on the above-measured amount every day and
when the weather condition changes

Measurement of water rate of fine aggregate Adjustment of Job-mix formula at the site

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 3. Compression test

• Judged theTest results shall not be less than 85% of the design strength
• Average of 3 consecutive test results shall be not less than the design strength
 test results of the average of one pair test specimens at one time
 Using the below graph, the concrete production procedures shall be checked
 If the test values become stable enough for secure design strength, it is possible to
change the job-mix formula to decrease cement and water volumes during the
project

Target strength 38.3 MPa Ave. of 28 days strength

Strength of concrete pressure

Design strength 115% of design strength

30.0 MPa 34.5 MPa
85% of design strength 25.5 MPa
Ave. of 7 days strength

Order of the data

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4. Common mistakes in the field

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 Common mistakes Check sheet
Mixture of different kinds of aggregate in the silo 1 ． Reference regulation

General Specifications for Freeways and

Toll Roads, August 2020 (Fine and course
aggregate shall be stored separately to
prevent contamination by foreign material)

2. Activities of PMI
Deferent
type of Periodically go to the batching plant
aggregate Monitor different kinds of aggregate
mix or not

Suggest improvement methods

Record the situation periodically to

DGH

3. Activity of DGH
Deferent
type of Monitor the situation of aggregate
stock yard by the report from PMI
aggregate

Discuss with BUJT about the

countermeasure, if the mixture
different aggregate continues

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 Common mistakes Check sheet
Mixture of different kind of aggregate in the stock yard 1 ． Reference regulation
General Specifications for Freeways and
Toll Roads, August 2020 (Fine and course
aggregate shall be stored separately to
prevent contamination by foreign material)

2. Activities of PMI
Periodically go to the batching plant
Monitor different kinds of aggregate
mix or not

Suggest improvement methods

Record the situation periodically to

DGH
3. Activity of DGH
Monitor the situation of aggregate
stock silo by the report from PMI

Discuss with BUJT about the

countermeasure, if mixture different
Deferent type of aggregate aggregate continue

12
5. Good practice in the field

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(1) Sprinkler in the stock yard General Specifications for Freeways and Toll
Roads, August 2020 (Aggregate shall be
stored so as to protect it from direct rays o the
sun

Photo in Indonesia

 Cooling aggregate is most effective for secure adequate temperature

of flesh concrete no more than 35℃
 If there is no sprinkler, it is also effective for watering manually with a
hose periodically 14
(2) Name plate of aggregate General Specifications for Freeways and Toll
Roads, August 2020 (Fine and course
aggregate shall be stored separately to
prevent contamination by foreign material)

Photo in Indonesia

 Plates with names of aggregate are effective to prevent placing

aggregate in the wrong place by suppliers 15
(3) Roof on the aggregate silo General Specifications for Freeways and Toll
Roads, August 2020 (Fine and course
aggregate shall be stored separately to
prevent contamination by foreign material)

There in no roof on the silo in other

project

Photo in Indonesia

 There is a roof on the silo for

preventing rain water into the fine
aggregate and securing the
temperature of the aggregate not Photo in Indonesia
increasing high 16
(3) Roof in the aggregate stock yard
General Specifications for Freeways and Toll
Roads, August 2020 (Fine and course
aggregate shall be stored separately to
prevent contamination by foreign material)

There in no roof in other project

Photo in Indonesia

 There is a roof in the aggregate stock

yard for preventing rain water into the
fine aggregate and securing the
temperature of the aggregate not Photo in Indonesia
increasing high 17
(4) Roof on the belt conveyer

There in no roof on the belt conveyer

in other project

Photo in Indonesia

 In some project, there is roof on the belt

conveyer for preventing rain water
into the fine aggregate, and
aggregate scatter around
Photo in Indonesia
18
(5) Enclosed water tank

No roof on the water tank in other project

Photo in Indonesia

Enclosed water storage tank is used in

some project for preventing debris and other
materials into the water tank

Photo in Indonesia
19
(6) Name plate of the inlet of cement silo

No plate of inlet of silo in other project

Photo in Indonesia

When several kinds of cement are used,

name plate is effective to prevent
misunderstanding of inlet by supplier
Photo in Indonesia
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(7) Drainage facilities of batching plant is well
maintained

Drainage not enough in other project

Photo in Indonesia

Sewage in the batching plant yard is

being well treated in some projects

Photo in Indonesia
21
(8) Test pieces are stored in separate tanks for each
day of the week

In some project, test pieces are not stored in

order, and it is difficult to find the pieces

Photo in Indonesia Photo in Indonesia

Test pieces are stored in separate water tanks for each day of the week.
The date, place, and kinds of concreting are clearly indicated in the test
pieces 22
(9) Concrete mixer is well cleaned periodically

Inside of the mixer is not cleaned

Photo in Japan Photo in Indonesia

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