Rest the shovel, pump the concrete

Swift operation: Transit mixers, specially made trucks, take ready-mix concrete from a centrally located factory called batching plant to the worksite. Ready-mix concrete offers the advantages of low cement wastage, optimum use of water, and precise mixing. R. Ramabhadran Pillai reveals a plan of the KSIDC to set up a ready-mix plant in Kochi Technology has helped improve execution of work in various sectors. Ready-mix concrete, product of better technology, has made much impact in the construction sector. The product is much useful when building sites are situated in congested areas where mixing of concrete is practically impossible. The Kerala State Industrial Development Corporation (KSIDC) is proposing the setting up of a ready-mix concrete plant in Kochi against such a background. Ready-mix concrete is ready to be used, with cement, sand, metal, and other additives mixed as required by the client. It is manufactured in a centrally located factory (batching plant) and delivered to the worksite, generally in special trucks known as transit mixers, capable of mixing the ingredients en route. Many project managers prefer ready-mix concrete to on-site mixing, as the product is made with more precision. Speedy construction through convenient delivery at the project location is another advantage. The mechanised operation proves to be economical as well because labour and supervisory tasks are reduced considerably. Quality The system ensures consistent quality, reduction in cement wastage, and optimum use of water, resulting in faster completion of the project. Pollution arising out of cement mixing is reduced on the project site. A KSIDC report says the ready-mix concrete business in India is still in its infancy. Nearly 80 per cent of the cement consumption in developed countries is in the form of ready-mix concrete and 20 per cent in the form of recast. In India, ready-mix concrete accounts for less than 5 per cent of the cement consumption. In contrast, 70 per cent of the cement produced in a developed country such as Japan is used by the ready-mix concrete business, the report says. The growth of ready-mix concrete business in India is predominantly driven by demand from metros and Tier-2 cities. But now, since the focus has shifted to Tier-3 and -4 cities, the demand for it has shown a steady increase. Anticipating a huge potential for the product, several major manufacturers of cement have launched ready-mix concrete. Its share is expected to go up from the present level of less than 5 per cent of the total cement production to the global average of 70 per cent, industry players say. The production capacity of a ready-mix concrete plant depends on the capacity of the batching plant. An average plant has a production capacity of 30 cubic metres per hour. The plant will be able to produce about 90,000 cubic metres a year. Availability of raw materials, such as sand, metal and water, apart from cement, are to be considered before deciding on the location of the plant. Kochi is considered suitable as the ingredients can be made available without much difficulty. A unit will consist of a batching plant, a transit mixer, and a concrete pump. The cost of machinery for a plant with a capacity of 30 cubic metres per hour is around Rs.2 crore. The total cost of the project will be Rs.4 crore. The plant will have to employ 20 persons. The KSIDC project will be executed with private participation. Keywords: ready mix concrete