Setting up a Ready-Mix Concrete Manufacturing Plant. Ready-Mix Concrete (RMC Plant) with Concrete Blocks, Batching, Mixing & Transporting Concrete

Ready-mix concrete (RMC) is a type of concrete which is manufactured in a cement factory, or specifically known as the batching plant, according to a given set of proportions, and then delivered to a work site, by truck mounted with mixers. This results in a precise mixture, allowing specialty concrete mixtures to be developed and implemented on construction sites. Ready mix concrete is sometimes preferred over on-site concrete mixing because of the volume it can produce with precision of proportion of mixtures and also due to reduced work site confusion. Using a pre-determined concrete mixture reduces flexibility, both in the supply chain and in the actual components of the concrete.

Ready mixed refers to concrete that is batched for delivery from a central plant instead of being mixed on the job site. Each batch of ready-mixed concrete is tailor-made according to the specifics of the contractor and is delivered to the contractor in a plastic condition, usually in the cylindrical trucks often known as "cement mixers."

Ready-mixed concrete is particularly advantageous when small quantities of concrete or intermittent placing of concrete are required. Ready-mixed concrete is also ideal for large jobs where space is limited and there is little room for a mixing plant and aggregate stockpiles.

Ready-mixed concrete is often remixed once it arrives at the jobsite to ensure that the proper slump is obtained. However, concrete that has been remixed tends to set more rapidly than concrete mixed only once. Materials, such as water and some varieties of admixtures, are often added to the concrete at the jobsite after it has been batched to ensure that the specified properties are attained before placement.

Ready-mix concrete is also termed as the customized concrete products for commercial purpose. Ready-mix concrete (RMC) refers to concrete that is specifically manufactured for delivery to the customer’s construction site in a freshly mixed and plastic or unhardened state. Concrete itself is a mixture of Portland cement, water and aggregates comprising sand and gravel or crushed stone. In traditional work sites, each of these materials is procured separately and mixed in specified proportions at site to make concrete. Ready-mix concrete is bought and sold by volume – usually expressed in cubic meters (cubic yards in the US).

Advantages of Ready Mixed Concrete:

·         Quality assured concrete: - Concrete is produced under controlled conditions using consistent quality of raw material.

·         High speed of construction- Speed of construction can be very fast in case RMC is used.

·         Reduction in cement consumption by 10 – 12 % due to better handling and proper mixing. Further reduction is possible if mineral admixtures or cementitious materials are used.

·         Versatility in uses and methods of placing: The mix design of the concrete can be tailor made to suit the placing methods of the contractor.

·         Since ready mixed concrete (RMC) uses bulk cement instead of bagged cement, dust pollution will be reduced and cement will be saved.

·         Conservation of energy and resources because of saving of cement.

·         Environment pollution is reduced due to less production of cement.

·         With better durability of structure, their overall service life increase and there is saving in life-cycle cost.

·         Eliminating or minimizing human error and reduction in dependency on labour.

·         Timely deliveries in large as well as small pours.

·         No need for space for storing the materials like coarse and fine aggregate, cement, water and admixtures.

·         No delay due to site based batching plant erection/ dismantling; no equipment to hire; no depreciation of costs.

·         Reduced noise and air pollution; less consumption of petrol and

·         Diesel and less time loss to business.

Uses:

1.       It is used in the construction of bridge, dam etc.

2.       It is used in the construction overhead roads, pools, multistoried building etc.

3.       It can be directly used at the construction site.

4.       It help greater element of automation and precision concrete mixing.

5.       A much higher quality and more constituent uniformity and increase standardization and speed which is done ten times faster as compared to site mixed concrete.

The growing number of infrastructure projects, including bridges, roads, dams, and airport expansion works, especially in developing nations is fueling the demand for ready-mix concrete. The global ready-mix concrete market is thus expected to witness high growth in the coming years. Some of the other reasons behind the growth of the market are high government spending on construction, manufacturing, and power plants, the growing population, and the trend of urbanization.

On the basis of application, the global ready-mix concrete market can be segmented into commercial building, industrial utilities, residential buildings, and infrastructure. The construction of highways, renovation of airports, and construction of dams will lead to the rapid growth of the infrastructure segment. The rise in the budget allocations by governments for infrastructure development will also prove to be beneficial.

The global ready-mix concrete market can be segmented on the basis of geography into Asia Pacific, North America, Europe, and the Rest of the World. Of these, it is most likely that Asia Pacific will lead in the market owing to a growing number of new infrastructural projects in India, Singapore, China, and Thailand. Rapid industrialization and urbanization in these countries are behind the growth of the market in Asia Pacific.

RMC is being increasingly used as a building material for residential & commercial buildings, manufacturing facilities, energy generation plants, roads and runways. Infrastructure development in emerging economies coupled with increasing trend of urbanization are some of the key factors which are expected to drive industry growth over the forecast period.

Growing construction spending in light of urbanization, population growth and government infrastructural plans will increase market growth. The government of India launched smart cities program to create cities equipped with good infrastructure offering high quality of life through smart solutions, which is likely to spur the demand for RMC.

The demand for commercial buildings such as offices, schools, colleges, hospitals and shopping malls is increasing owing to rapid economic development and modernization is expected to fuel market demand over the upcoming years. Moreover, development of new Greenfield airports, metro railway stations, stadiums and national highways will further drive the usage of ready-mix concrete in the future. However, developed infrastructure in countries such as Germany and the U.S. is expected to restrict the usage of RMC and serve as the major challenge for manufacturers over the forecast period.

Growing population and rapid economic development in emerging countries including China, South Korea, and India are expected to propel the demand for construction of commercial buildings such as shopping malls, schools, offices, colleges, banks, and hospitals.

The global ready-mix concrete market is expected to reach USD 954.7 billion by 2024. An increasing number of infrastructure projects including roads, bridges, dams coupled with rapid airport expansion works in emerging countries will fuel growth over the next eight years. Furthermore, rising government spending on power plants, manufacturing facilities, construction infrastructure along with the growing population will augment industry expansion over the upcoming years.

Though the RMC sector in India is growing rapidly at a pace of 25-30 per cent annually the business is still in its infancy – the gap between the organized and unorganized sector wide. In industrialized countries ready mix concrete forms around 70-75 per cent of the market share. With India building up its infrastructure and cities see a spurt in Verticalization the ready mix sector is expected to play an increasingly dominant role mainly because it is seen as the most viable option to speed up construction. RMC is also being increasingly preferred alternative for most real estate developers because site mixed concrete is dependent on the availability of labour.

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