How do you cross check the RMC plant batch report with a design mix of concrete?
How do you cross check the RMC plant batch report with a design mix of concrete?
- Thread starter Sumit Civil
- Start date
Dnyan Deshmukh
Staff member
When a truck arrives at the placing location, truck driver do have a Challan which gives the details of placing location, mix details, and vehicle details along with quantity. There is one more sheet they have with them called as batch report or batch sheet.
Concrete at RMC plants loaded in batches of 0.5 or 1 cum or any specific batch size depending on the mixer capacity at RMC Plant.
During production stage, the each batch details are recorded into computer and printed on completion of batching of concrete.
Batch reports do have the details of each ingredient batched in each batch of concrete, those values remain same as of Concrete mix design until there is moisture in aggregates, moisture aggregates can be caused due to rain or fogging done at plant to reduce dust pollution.
If the values are not same, we should ask for batch correction reports in which what are the corrections done for aggregates and water quantity are mentioned in scientific way.
At the end of the batch report, you find a lines which shows variance in the batch concrete, variance in the batched concrete can be caused due to acceptable limits given to the PLC for each batch of concrete.
We should check for following in batch report;
Quanity of Cement and Cementitious materials - as its the main factor for strength.
Quantity of water batched and water cement ratio - Is another main factor for strength.
Quantity of admixture - also plays very important role in providing workability and performance.
all Aggregates quantity - which makes a concrete as concrete.
Finally the variation or difference in the batched quantity and set quantity - it should not be more than the specified limits.
Concrete at RMC plants loaded in batches of 0.5 or 1 cum or any specific batch size depending on the mixer capacity at RMC Plant.
During production stage, the each batch details are recorded into computer and printed on completion of batching of concrete.
Batch reports do have the details of each ingredient batched in each batch of concrete, those values remain same as of Concrete mix design until there is moisture in aggregates, moisture aggregates can be caused due to rain or fogging done at plant to reduce dust pollution.
If the values are not same, we should ask for batch correction reports in which what are the corrections done for aggregates and water quantity are mentioned in scientific way.
At the end of the batch report, you find a lines which shows variance in the batch concrete, variance in the batched concrete can be caused due to acceptable limits given to the PLC for each batch of concrete.
We should check for following in batch report;
Quanity of Cement and Cementitious materials - as its the main factor for strength.
Quantity of water batched and water cement ratio - Is another main factor for strength.
Quantity of admixture - also plays very important role in providing workability and performance.
all Aggregates quantity - which makes a concrete as concrete.
Finally the variation or difference in the batched quantity and set quantity - it should not be more than the specified limits.
asadsmysore
Newbie
Dnyan Deshmukh
Staff member
As per this batch report after verification of the billing details, Qualitative analysis can be done as follows;
This batching plant has the batch size of 0.5 cum - this means it can produce maximum 0.5 cum of concrete in 1 batch.
It shows concrete quantity produce and loaded in truck as 4.5 cum so there will be total 9 batches printed on report (4.5 cum / batch size = 0.5)
Now check the targeted values for concrete production are as per mix design. as the mix design is for cum and batch size is 0.5 cum, the half of the values will be targeted for production.
After production of the concrete the complete batch report will be printed and it indicates actual value of each material batched into each batch - Verify those values (this will help you to understand what tolerances are in place for batching).
After every batch depending on the actual weight taken to produce concrete, the software auto adjust the target values for next batch and it continues till the production cycle is complete. (You can also get that printed on your batch report when you specify for the same and genuine concrete producer can also provide batch reports with those details, this helps to get assured that, batch reports are not fake).
After going through all values printed for each batch, at last you will get a total material values gone into the concrete and Total theoretical value required for producing that volume. you can check weather the variation in actual vs theoretical values for each material is within the specified limit or not.
The only important thing in verification of batch report is mix design values matches with produce concrete materials value and they are within specified tolerance limit.
Pravin@kapp
Newbie
Dear sir,
How we checked whether cement is mixed in batch or not, if some times weigh batcher printing issue occurred and is ther any chemical test is there to indentify cement is released to batch or not?
Dnyan Deshmukh
Staff member
The possibility of cement is not discharge while batching is very rare and can happen only when plant is malfunctioning.
In auto mode when cement is not discharged, the batching cycle wont complete automatically and if some one wish to complete then the batching need to be done in manual mode which does not output the batch report of the production as the batching cycle was terminated.
Running a plant in manual mode only happens when there is malfunctioning - which need to be sort out immediately.
if there is a issue in printer you can ask for soft copy of the report or screen shot for doing assessment of supplied concrete.
It is difficult to find the exact content of cement in mix and the technique available if any would be very costly, instead deploying a person to monitor batching would be cheaper.
There are the ways to know the cement content of hardened concrete prescribed in IS 516 part 11, 2020. but again instead of doing postmortem it is better to have preventive control in place i.e. deployment of person to monitor batching of concrete.
In auto mode when cement is not discharged, the batching cycle wont complete automatically and if some one wish to complete then the batching need to be done in manual mode which does not output the batch report of the production as the batching cycle was terminated.
Running a plant in manual mode only happens when there is malfunctioning - which need to be sort out immediately.
if there is a issue in printer you can ask for soft copy of the report or screen shot for doing assessment of supplied concrete.
It is difficult to find the exact content of cement in mix and the technique available if any would be very costly, instead deploying a person to monitor batching would be cheaper.
There are the ways to know the cement content of hardened concrete prescribed in IS 516 part 11, 2020. but again instead of doing postmortem it is better to have preventive control in place i.e. deployment of person to monitor batching of concrete.
