Ready-mixed Concrete Industry Research Articles

Quality Management In Ready-Mix Concrete Production In Zambia

The construction industry, a significant contributor to global economies, is projected to yield substantial economic output by 2030 of around $135 trillion. Central to construction is concrete, a widely used material. Ready-mix concrete (RMC), a specialised form of concrete, is gaining prominence due to its rapid setting and superior quality. In Zambia, the increasing demand for RMC highlights the need for stringent quality management to hedge potential structural risks. This study aimed to determine the quality management in ready-mix concrete production in Zambia. Employing a parallel convergent mixed-methods research design to achieve the objectives, qualitative data was collected through semi-structured interviews and desk study and quantitative data was gathered through a structured questionnaire and an observation checklist. The findings of the study reveal that while guidelines exist, adherence varies. Regulatory bodies for standards, engineering and construction play pivotal roles in overseeing RMC quality. However, their execution faces inconsistencies and challenges due to limited resources and a lack of sense of responsibility. Quality control practices were investigated unveiling variations in forward, immediate, and retrospective control phases. Notable trends in proper storage and equipment calibration showed a commitment to precision. Immediate control practices, encompassing sampling and non-compliance management, demonstrated both positive aspects and areas for improvement. Retrospective control showed commitment to comprehensive strength testing and minimal towards split cylinder testing and on-site slump evaluation. In the realm of quality assurance (QA), RMC facilities show substantial adherence to documented QA standard operating procedures and thorough raw material inspections. However, deficiencies in batching and mixing practices and limited adoption of modern weighing systems require improvement. The study recommends creating an industry association for collaboration, enhancing standardised practices, introducing third-party quality audits, and proposing compulsory RMC standards to boost progress in the Zambian RMC industry. Key Words: Quality Management, Ready Mix Concrete, Observation, Desk Study, Zambia.

Evolution, Challenges, and Opportunities in Ready Mix Concrete (RMC) Industry in India

Abstract: The Ready Mix Concrete (RMC) industry has undergone significant evolution since its inception, transforming the construction landscape with its efficiency and reliability. This paper provides a comprehensive analysis of the evolution of the RMC industry, tracing its origins, key milestones, and technological advancements. It also examines the challenges facing the RMC sector, including regulatory hurdles, supply chain constraints, and environmental concerns. Furthermore, the paper explores the opportunities for growth and innovation within the RMC industry, such as embracing digitalization, sustainable practices, and market diversification. By understanding the evolution, addressing the challenges, and seizing the opportunities, stakeholders can navigate the dynamic landscape of the RMC industry and drive its continued advancement.

Evaluation of the implementation an active fire protection system in production unit PT. Wijaya Karya Beton Tbk. Pasuruan

PT Wijaya Karya Beton Tbk. Pasuruan is a manufacturing company engaged in the ready-mix concrete industry. One of the potential unpredictable hazards during the concrete production process is fire. Fire is an unwanted ignition that is difficult to control, as it can result in losses of property, loss of life, and the interruption of the production process. Therefore, the objective of this research is to evaluate the compliance of the active fire protection system as a preventive and mitigating measure against the fire hazard at PT Wijaya Karya Beton Tbk. Pasuruan. The research is observational and uses a descriptive method. The research findings indicate that the level of compliance with the implementation of the active fire protection system at PT Wijaya Karya Beton Tbk. Pasuruan averages 83.33%. The evaluation of the implementation of fire extinguishers according to NFPA 10 is categorized as good (91%), the evaluation of hydrant implementation according to SNI 03-1745-2000 and Minister of Public Works Regulation No. 26/PRT/M/2008 is categorized as good (90%), and the evaluation of the implementation of fire alarms according to NFPA 72 is categorized as sufficient (68%). In conclusion, the compliance of the active protection system at PT Wijaya Karya Beton Tbk. Pasuruan is considered to be in the good category.

Study on the properties of autoclaved aerated concrete with high content concrete slurry waste

Concrete slurry waste is solid waste produced in the ready-mixed concrete industry, which will cause serious pollution to the environment. This paper mainly studies the physical and mechanical properties and microscopic products of autoclaved aerated concrete with high content concrete waste slurry. Attempts are made to improve the mechanical properties of the product by using nano-silica and silica fume. The flowability and gas foaming characteristics of the slurry, the dry density, the compressive strength, and the reaction product of the product were analyzed. The experimental results show that with the content of concrete slurry waste reaching 60%, the dry density and compressive strength of AAC are 470.5 kg/m3 and 2.16 MPa, respectively. On this basis, the dry density and compressive strength of AAC with the addition of 1% nano-silica and 7% silica fume are 512.8 kg/m3, 3.05 MPa, and 462.52 kg/m3,2.86 MPa, respectively.

A Study on the Application of Green Retrofitting in the Ready-Mix Concrete (RMC) Industry in Indonesia to Improve Cost Retrofitting Performance

A Study on the Application of Green Retrofitting in the Ready-Mix Concrete (RMC) Industry in Indonesia to Improve Cost Retrofitting Performance

Protecting Small-Scale Enterprises: Evidence from the Korean Ready-Mixed Concrete Industry

Protecting Small-Scale Enterprises: Evidence from the Korean Ready-Mixed Concrete Industry

Feasibility of Digital Twins to Manage the Operational Risks in the Production of a Ready-Mix Concrete Plant

The ready-mix concrete supply chain is highly disruptive due to its product perishability and Just-in-Time (JIT) production style. A lack of technology makes the ready-mix concrete (RMC) industry suffer from frequent production failures, ultimately causing high customer dissatisfaction and loss of revenues. In this paper, we propose the first-ever digital twin (DT) system in the RMC industry that can serve as a decision support tool to manage production risk efficiently and effectively via predictive maintenance. This study focuses on the feasibility of digital twins for the RMC industry in three main areas holistically: (1) the technical feasibility of the digital twin system for ready-mix concrete plant production risk management; (2) the business value of the proposed product to the construction industry; (3) the challenges of implementation in the real-world RMC industry. The proposed digital twin system consists of three main phases: (1) an IoT system to get the real-time production cycle times; (2) a digital twin operational working model with descriptive analytics; (3) an advanced analytical dashboard with predictive analytics to make predictive maintenance decisions. Our proposed digital twin solution can provide efficient and interpretable predictive maintenance insights in real time based on anomaly detection, production bottleneck identification, process disruption forecast and cycle time analysis. Finally, this study emphasizes that state-of-the-art solutions such as digital twins can effectively manage the production risks of ready-mix concrete plants by automatically detecting and predicting the bottlenecks without waiting until a production failure happens to react.

Towards an eco-efficient ready mix-concrete industry: Advances and opportunities. A study of the Metropolitan Region of Buenos Aires

There is a growing demand in Latin America and the Caribbean for building materials to satisfy the need for adequate housing and infrastructure in urban areas. This paper examines the consumption of materials and environmental impact of ready-mix concrete produced in the Metropolitan Region of Buenos Aires in a certain period of time. Material flow analysis and life cycle assessment (LCA) were performed. The average composition concrete was estimated by means of surveys conducted with ready-mix concrete producers. The material efficiency (ME), CO2 equivalent emissions (ECO2eq), materials and energy use were used as environmental indicators. Feasible impact reduction strategies and their influence on the LCA were also explored. 7.16 Mt of materials were required to produce 2,604,862 m3 of ready-mix concrete, within 99.1% corresponded to raw materials, while 0.9% corresponded to secondary raw materials. 5.36 Mt (∼78.6%) of the extracted materials belong to aggregate production and they represent ∼19.5% of the ECO2eq. Portland cement is the largest contributor to ECO2eq and the constituent material with the lowest ME. Using recycled aggregates is the strategy that contributes the most to the reduction of the use of raw materials (∼8.9% lower use of raw material by using 20% recycled coarse aggregate), while replacing Portland cement with supplementary cementitious materials (SCM) is the one that reduce the most the ECO2eq (the use of Portland cement without SCM would increase ECO2eq by ∼13.6%). This research provides a novel approach that quantifies the effect of modifying the concrete mix and replacing raw materials by secondary raw materials, bringing a new understanding to the sustainability of building materials.

Exploring Blockchain-enabled smart contracts technology implementation within ready-mixed concrete plants industry in Saudi Arabia

In recent years, several construction-related services incorporating Blockchain-enabled smart contracts have emerged. Blockchain-enabled smart contracts have the potential to modify the structure of all accessible networks in the near future. The purpose of this study is to explore individuals understanding of smart contracts in Saudi Arabia, identify potential advantages, and assess actors' readiness to implement smart contracts technology in ready-mixed concrete (RMC) plants. Data was acquired by questionnaires distributed to employees from Saudi Arabia's RMC plants companies. Additionally, confirmatory interviews were conducted out to areas of expertise. The study's findings revealed a low level of smart contract knowledge within Saudi Arabia’s RMC plants sector. The readiness to implement smart contracts is extremely low. According to the findings, smart contracts can improve supply chain management and supply chain finance efficiency, but not in the current circumstances in Saudi Arabia owing to insufficient digitization.

Development of an Internal Safety Evaluation Program for Ready Mixed Concrete Producers

The aim of this study is to assist the safety specialists and departments in ready mixed concrete (RMC) industry by preparing an internal safety evaluation program (ISEP). To constitute an ISEP the 287-item control list was created and grouped as negligible, moderate, and critical. The control list was applied to thirteen RMC plants which belongs to one RMC company. It is found that even the same company cannot ensure stability in terms of OHS between its plants, none of the plants had an approved OHS policy, emergency action plan and a plant entrance OHS warning sign. OHS training was mostly missing in plants.

Increasing Profits of Ready-Mix Concrete by Using Cutting-Edge New Additive

A new revolutionary patented additive for concrete was used in series of trials to check for its suitability to Ready-mix Concrete industry. Commercial production of Concrete was also taken up to check the fresh and hardened properties of additive incorporated concrete. The study showed that additive (commercially known as ICRETE) showed impressive results in concretes as it demonstrated comparable strengths even at reduced Cement contents. In addition the striking feature of the product is to improve the profits forReady-mix Concrete producer, without affecting the quality & durability.

Impact of COVID-19 on ready-mix concrete (RMC) industry in Ahmedabad – A case study

India witnessed its first case of coronavirus infection (COVID-19) on January 27, 2020, in Kerala, India. Since then, the infection has spread rapidly across the country and the pandemic outbreak has affected all industries severely including the construction sector. This study aims to understand the effect of the COVID-19 pandemic on the construction sector, particularly the ready-mix concrete (RMC) industry. An attempt was made to investigate the liabilities and the losses incurred by the RMC industry in terms of income and change in the production of concrete during the coronavirus outbreak. A preliminary survey was carried out to create a database of the RMC plants located nearby the study area i.e., Ahmedabad City in the state of Gujarat, and to prepare a questionnaire using google forms. The RMC plants were visited and from the inputs of RMC officials, statistical insights were drawn. The study reveals that during the COVID-19 lockdown period there was almost a 40% loss in concrete production & 60% loss in the income generated by the ready-mix concrete industry. In addition to this, it was also found that the industry had to pay off liabilities like land rent, electricity bills, staff salaries, etc. during the time of the pandemic. This study provides the opportunity for RMC plants to identify the vital elements involved in the operation of the plant which can be affected due to such pandemic and provides guidelines to reduce the effect of any such pandemic on the plant’s production & sales by ensuring the stability of all assets involved in its supply chain.

Risk Management in Ready Mixed Concrete (RMC) Plant by Using FMEA and ANP

Due to technological development, gigantic skyscrapers and mega projects are possible resulting into increased demand of concrete for these projects. In municipal areas, site locations are in congested places where manual mixing is not possible. As Ready Mixed Concrete (RMC) is favoured more as it provides concrete of required quality and of required quantity. The success of RMC industry depends upon proper identification and assessment of risks or failure modes involved in various stages in concrete production. RMC industry is extremely complex in nature which contain many uncertainties resulting into complex risk management methodologies. The main aim of the research is to determine most critical risk that can occur at Ready Mix Concrete (RMC) plant and to provide suggestions to mitigate the most critical risk or failure modes. To achieve this aim, Failure Mode Effect Analysis (FMEA) is used combined with Analytical Network Process (ANP) to access and prioritize the risks involved at RMC plant as six risks resulted into same Risk Priority Number (RPN). Finally, it was concluded that injury at site is most critical risk involved at RMC plant. The research also provides suggestion to mitigate most critical risk.

Influence of Concrete Sludge Addition in the Properties of Alkali-Activated and Non-Alkali-Activated Fly Ash-Based Mortars

This study investigated the use of concrete sludge, a by-product of the ready-mix concrete industry, in combination with high-calcium fly ash in binary cementless binders. Concrete sludge was used in substitution rates ranging from 0% to 60% in test fly ash-based mortars to determine potential synergy. The mortars were tested for fresh and hardened properties; workability, viscosity, strength development, open porosity, early-age shrinkage, and analytical tests were carried out. A mortar with 50% fly ash and 50% limestone filler as binders was used for comparison purposes. Furthermore, a series of mortars with fly ash and concrete sludge were alkali-activated in order to determine potential strength gain. In the activated mortars, two fractions of concrete sludge were used, under 75 μm and 200 μm, due to different silicon oxide contents, while one mortar was cured at 40°C to investigate the effect of heating on alkali activation. Results show that sludge contributes to the formation of C-S-H and strength development when used in combination with high-calcium fly ash even at high replacement rates. The alkali activation of fly ash-concrete sludge system contributed to early-age strength development and to early-age shrinkage reduction.

레미콘산업의 노사상생 방안에 관한 연구 -레미콘 사업자와 운송차주 간 갈등을 중심으로-

레미콘 사업자와 운송차주 간 갈등으로 인한 경제 사회적 손실이 불어나고 있다. 직접적 원인은 운반비 관련 이견이지만 그 이면에는 법적 근로자성을 인정받지 못하는 특수형태 근로종사자인 레미콘 운송차주들의 열악한 사정이 자리한다. 이런 갈등을 타파하고 경제 사회적 손실을 줄이려면 레미콘 노사와 정부가 머리를 맞대야 한다. 노동법상 사각지대에 놓인 레미콘 운송차주를 보호하기 위한 헌법상 노동3권을 인정하되, 이로 인한 부담을 안게 될 레미콘 사업자를 위해 믹서트럭 수급조절제 폐지, 레미콘 제값받기를 위한 중소기업조합의 공동판매 구매허용, 그리고 다각적 재정 세제 지원을 병행하는 빅딜의 형태가 바람직하다.<BR> 당정으로선 급증하는 플랫폼 노동자를 포함한 특수형태 근로종사자 문제를 풀어내는 정책 테스트베드 효과에 더해 주택 등 건축물과 SOC시설물 부실에 대한 국민적 우려를 불식하는 계기가 될 수 있다.

Thermal Transmission Properties of Sustainable Concrete with Supplementary Cementitious Materials

Understanding the thermal properties of a construction material is necessarily to evaluate its heat transfer resistance that has a major contribution to the energy-efficiency required to achieve sustainable structure. Thermal properties are evaluated through three main parameters namely: thermal conductivity, thermal resistivity and thermal transmittance. The aforementioned parameters are commonly referred as K-value, R-value, and U-value respectively. Recent regulations by Dubai municipality enforced to use sustainable concrete in construction. This is by replacing cement with supplementary cementitious materials (SCMs), such as grand granulated blast furnace slag (GGBS) and fly ash. The use of grand granulated blast furnace slag (GGBS) at relatively high percentage replacement became a typical practice in ready-mixed concrete industry in Dubai. As such, it is essential to characterize the thermal properties of this sustainable concrete. The current paper investigates the thermal properties of sustainable concrete mixtures incorporating supplementary cementitious materials, air entrainment additives, polypropylene and hybrid synthetic fiber. K-value, R-value and U-value are evaluated in accordance with ASTM C518. Additionally, hardened density of all investigated mixtures are measured. The results show that the foamed concrete has better heat transfer resistance than that for the non-air entrained mixture.

The Potential Use of Waste Cement as a Filler in Polymer Composites

This study explores the potential to use waste cement particles from ready-mixed concrete industry as a low cost filler in polypropylene. Its effects on mechanical and morphological properties were investigated in comparison with commercial cement and calcium carbonate. Mixing and shaping procedures of the polymer composites specimen were conducted by two-roll mill and injection molding, respectively. Next, the effect of filler loading (0, 10, 20, 30, 40, and 50 phr) and filler type on the mechanical and morphological properties of the polymer composites were studied. The results show that when filler loadings increased, the young’s modulus, flexural modulus, impact strength, and hardness of the polymer composites also increased accordingly, while the tensile strength and flexural strength decreased. Moreover, the results show that the waste cement had a greater effect on the enhanced mechanical properties compared to commercial cement and calcium carbonate. Furthermore, the polymer composites’ morphology was studied using scanning electron microscopy. A microstructure analysis was performed to verify and provide a better assessment of the performance properties of the polymer composites.

Impact of Retention of Slump on Growth of Ready Mixed Concrete

In these days the Ready Mixed Concrete (RMC) plants were giving a back bone support for construction and concrete industries. As the infrastructure increases, concrete demand also increasing proportionately due to huge benefits of concrete, consequently, number of ready mixed concrete plants were also increase proportionately to supply the concrete according to the demand. Those who are fed up with the site mixing and environmental problem associated with them, they are opting for RMC. The growth of RMC is increasing from metropolitan cities to villages. One of the key factors for the growth of RMC is retention of slump till reach the construction site by using super plasticizer. In the present study, the growth of RMC industry from 1990’s in India was presented. An experimental study was done on Slump retention capacity of concrete with fly ash, GGBS and lime Stone powder with 0.4% of admixture dosage.

Optimum usage of GGBS in Ready M ix Concrete Industry.

The construction industry plays a vital role in India’s development and it contributes about 8-10 per cent to GDP on an average. Developing nations like India need to have faster construction with high quality, durability and a pollution-free environment, which can be achieved only with Ready mix concrete (RMC). The usage of GGBS is very high in RMC industry. Compressive strength and workability are the most important and basic properties of concrete for any applications. An experimental investigation is carried out on optimum usage of GGBS in Ready Mix concrete industry. This paper presents the experimental test results of 27 types of concrete mixes made with 10% to 80% replacement of ordinary Portland cement. Slump retention for 180 minute which is a basic requirement for an RMC industry is carried out. Compressive strength testing of all the specimens was carried out at 7, 28, 56, 90 and 180 days. The test results proved that the compressive strength of concrete mix containing GGBS increases but after 50% of the total binder content, the addition of GGBS does not improve the strength of concrete. The reason could be GGBS may act as fine aggregate.

Evaluation on Protection Performance and On-Site Applicability of Hybrid Fiber-Reinforced Concrete

The aim of this research is to evaluate the protecting performance of hybrid fiber-reinforced concrete against lateral forces such as explosives or flying objects. The objective of this research is to better prepare this concrete for use in the ready-mix concrete industry. Even though the fiber addition gives it strong mechanical properties, it also decreases workability due to the inefficient dispersion of fibers. Therefore, it has been difficult to apply to the ready-mix concrete plant’s mixing, delivery and on-site placement. The authors have developed a combined steel and polyaramid fiber that gives the favorable protection needed against high-impact forces and provides a suitable workability for the ready-mix concrete system. To evaluate the required performance, the hybrid fiber-reinforced concrete specimen was subjected to high-speed projectiles and had its workability and performance tested on a construction site of an established ready-mix concrete company. The hybrid fiber-reinforced concrete successfully provided the protection capabilities sought for the finished product and provided a workable-ready mix applicability.