Implementation of Construction Management Approach for Improving the Productivity of RMC Plants

INTRODUCTION

Architect Jurgen Heinrich Magens initially proposed the concept of ready-mix concrete (RMC), and in 1903, he received a patent for the invention in Germany. He found in 1907 that shaking freshly-poured concrete while transporting it might extend the time for transportation in addition to cooling it. Thus, an off-site concrete was created as a result of this. In Baltimore, Maryland, in 1913, soon before the First World War, the first batch of concrete that was mixed off-site and brought to a building site was successfully completed. The expansion of the RMC business was aided by the new and rapidly expanding automotive industry's rising supply of special transport vehicles. In the United States, the first transit mixer idea appeared in 1926. The first RMC facility was built in the UK in 1939, and the country also saw the publication of the first RMC specifications in 1933. RMC production in the United States increased significantly between 1950 and 1980, reaching a peak supply of 31 million cubic metres in 1974. However, between 1974 and 1980, RMC supplies were 25 million cubic metres annually on average. In the United States, there were 3700 RMC firms by 1990, and they were using 75% of the cement used by the building sector. In 1990, the RMC factory in Japan used around 70% of the cement produced overall. Nearly 16% of the total cement consumed in Malaysia in 1990 was used in RMC plants. RMC factories utilise 43% of the total cement consumed in the UK.

RMC was originally employed in India in 1950 when dams like Bhakra Nangal and Koyna were being built. Concrete is moved throughout the building site either manually or mechanically using ropeways, buckets, or conveyor systems. the RMC in Pune in 1991. However, this factory did not last very long owing to several setbacks and issues, and it was shut down. Two RMC plants were established in Mumbai within a few months of one other in 1993 to commercially sell RMC to the projects where they were installed. One factory was built by Unitech Construction in the Hiranandani Complex, while another was built by Associated Cement Companies at the Bharat Diamond Bourse Commercial Complex. makers from outside of India quickly developed an interest in the Indian market, leading two extremely reputable companies—Fletcher Challenge Ltd. from New Zealand and RMC Ready Mix from the UK—to lay foot on Indian soil.

Significance: : India is seeing widespread infrastructure construction as a result of the substantial concrete demand. But the lack of labour and the lack of concrete-laying space prevents this demand from being fully met. The quality of concrete is frequently compromised by labour neglect, and there is a scarcity of space for cast-in-place building in major cities.Due of this, RMC concrete is widely used throughout the nation.However, these plants have several issues, and as a result, their usefulness is compromised. Effective construction management is needed to overcome this. Initiative, its premise, the difficulties encountered, and the opportunities in our nation, India, are all represented in this paper. Nowadays, practically all of the construction industry uses RMC concrete, which is employed when a job needs to be done quickly and efficiently. The majority of RMC facilities are found in seven major Indian cities, where they account for 30% to 60% of all the concrete utilised in those cities. RMC accounts for around 5% of all the concrete utilised in India. RMC is becoming more and more popular in cities for the obvious reasons of limited development area and the necessity to reduce environmental pollutants. This is true even though the cost is between 12% and 20% greater than site-mixed concrete. M. Takeyama, The Narihirabashi Plant of Tokyo Concrete Kogyo Co. produced the country's first batch of ready-mixed concrete (RMC) in November 1949. Any RMC facility located across the nation is now only a phone call away from providing RMC. However, in recent years, the expansion of already existing plants as well as the growth of new RMC facilities has resulted in an excessive rise in supply capacity relative to demand, which has significantly decreased the operation rate. Arjita Biswas. The environmental impact of sludge water disposal is developing as a result of the rising demand for ready-mixed concrete. A single concrete truck needs between 700 and 1300 gallons of wash water per working day. Untreated sludge water is not permitted for dumping into urban sewers due to the high levels of suspended particles and alkalinity. In general, two series-connected sedimentation basins are used in the sludge water disposal process. The first basin is used to collect leftover concrete and truck and concrete plant wash water. Each transit combination is cleaned with 120 to 200 litres of water to get rid of the sludge that has built up on the blades, wall, and floor of the transit mixer. Prof.Jyoti Trivedi, In European nations, people are aware of the significance of hazards and the methods for managing them. Operation managers in RMC factories in European nations are probably involved in risk management at manufacturing facilities and delivery locations. At the RMC facility in India, risk management does not receive adequate attention. Information acquired from many RMC facilities in India, including those in Mumbai, Navi Mumbai, Pune, Bangalore, and Noida, demonstrates that the Indian RMC industry does not follow a regular and appropriate risk management method. Without appropriate risk

OBJECTIVES

• To study of difficulties facing while operating the RMC plants in section wise by circulating the questionnaires on different RMC plants.

• To prepare the detailed remedial plan for each section to overcome the difficulties. Also prepare the checklist for each section for smooth functionality of RMC plant.

• To indentify the check list parameter for smooth functioning of RMC plant

Step no 1: Divide the functions of RMC plant in different sections then Prepare the detailed questionnaires for each section and circulated on different RMC plants to understand difficulties facing while operating the RMC plants Step no 2: Prepare the detailed remedial plan for each section to overcome the difficulties. Also prepare the checklist for each section for smooth functionality of RMC plant. Step no 3: To study of cost benefit analysis after implementing the remedial plan by taking suitable case study.

• Concrete demand by customer in developing area.

• Cost control on aggregate for size, shape and grading. Not exercised on a site

• Blocking of roads/approaches.

• Dust pollution.

Quality assurance. Restricted space.

• Speed on construction site.

• Economy management.

 Group the RMC plant's activities into several divisions. To better understand the challenges involved in managing RMC plants, prepare extensive questionnaires for each segment and distribute them to various RMC facilities.  Prepare a thorough corrective action plan for each component to address the issues. Additionally, create a checklist for each area of the RMC plant to ensure seamless operation.  By using an appropriate case study, to investigate the cost-benefit analysis following the implementation of the corrective plan.

1) Name of Plant Manufacturer 2) Type of Plant 3) Plant‘s Rated capacity, m3/hour 4) Type of Mixer* Rotating-drum type 5) Mixer batch size, m3 6) Storage Capacity Cement, tonnes- Fly ash, tonnes- Slag, tonnes- Other cementitous material, tonnes-

10-mm- 20-mm- 40-mm-

River sand Manufactured sand Crusher fines, tonnes or m3

Superplasticiser Retarder 10) Brief description of recycling facility, if any- 11) Number of trucks with rated capacities-

To assess the many causes of construction waste, the Relative Importance Index (RII) ranking approach was used. The most important causes of construction waste variables in the construction industry may be determined from the ranking given to each cause of construction waste. The RII has been applied in several fields to assess the relative significance of one thing to others. The relative relevance index for each cause was calculated using the algorithm below. The relative importance indices (RII) for each element were calculated using the five-point scale, which ranges from l (extremely low) to 5 (very high) as follows:

RII=

Where: W = Weight age given to each factor (ranging from 1 to 5) A is 5 (the highest weight) and N is the Total number of Respondents The RII value had a range from 0 to 1 (0 not inclusive), the higher the value of RII indicates that the more important

1 .Very highly affects 4. Less affects 2. Highly affects 5.Very less affects 3.Moderately affects

Results: From this data analysis the critical factor is Selection of site for RMC plant Remedial Measure: In the building and development industries, the location of the RMC plant is crucial. There are several factors to take into account while choosing a location for the RMC plant. The effects of the RMC plant on the environment must also be taken into account.Even if the site selection requirements for the RMC plant are perfect, we also take into account the plant's economic viability.A large region may be served by a central concrete batching facility.Despite the fact that the factories are situated in regions designated for industrial use, delivery vehicles can nonetheless reach inner cities or residential areas.The local material supply should be close to the intended RMC plant location. The site chosen should be remote from residential zones to lessen the effects of noise and dust pollution on the neighbouring residential areas.The intended site location's transportation infrastructure for the RMC plant should be taken into account.The RMC plant should be situated in such a way as to balance out residential neighbourhoods and construction zones, and it should be able to operate around-the-clock when necessary.The ideal site placement should be close to regions with the highest potential for output.It should be simple to get skilled employees close to the preferred site location of the RMC facility.RMC plant waste should be conveniently disposed of without having an impact on the regions close to the chosen site location.

From this group 2 Lack of Resource is the critical factor

Cement, aggregates, fly ash, ggbs, chemical admixture, water, and other resources are needed for the RMC plant to operate effectively in the intended site location. Additionally, it is important that these resources are inexpensive and conveniently accessible near the RMC plant in order to run the RMC plant efficiently. Process management is concerned with the coordinated planning, organising, and control of the regarded every resource that is employed directly or indirectly in the production of a good. Various resources used in RMC plant should have consistent deliveries to the RMC plant so that there will not be delay in further processes in RMC plantmanufacturing the product

Result: From this group 3 :Lack of Supervision is the critical factor Remedial Measure In the RMC plant's production unit, supervision is a must. In the RMC plant, supervision is required for all activities. When producing concrete at the RMC plant, supervision is essential. Another crucial component of labour labour is supervision. In the RMC plant, supervision is responsible for planning and organising the production of concrete. The act or duty of watching over something or someone is known as supervision. A supervisor is someone who exercises supervision.To supervise is to monitor staff members' work. The individual providing supervision may not have a formal title or may have the title of manager or supervisor, with the latter having greater authority.In general, supervision involves imparting information, assisting with task organisation, boosting motivation, and keeping an eye on activities and outcomes; the proportion of each aspect varies.

Result: From this group : Waterproof Cement Silos is critical factor

Result: From this group : Quality of water is critical factor Remedial Measure Concrete preparation depends significantly on the water's quality. Water impurities can negatively impact the strength and durability of concrete as well as the cement's ability to set. Water's chemical components may actively engage management of such water must be taken into account. It is possible to determine whether water is suitable by looking at prior service records or by having it tested against performance standards including setting times, compressive strength, and durability tests. For combining water with its components, such as total alkalis, chloride sulphate, etc., limits are set. Saline water and recycled water handling safety is additionally ensured through biological treatment and pathogen reductions.

Ready to Eat A recent method of producing concrete in huge quantities away from the actual placement location is called concrete. It is extremely helpful in cities with high concrete demand and congested building sites where on-site mixing is impractical. RMC manufacturing has lower manpower and supervision expenses, and the concrete is of higher quality. It is appropriate for huge industrial and residential projects when timing is crucial.RMC activities are heavily automated and completely under electronic control, which lowers the likelihood of mistakes in a variety of procedures. Additionally, it is ecologically beneficial and reduces pollutants brought on by building site dust, which may also. The current study created a structure that helps the director of the RMC plant resolve his or her issue.We thoroughly investigated the RMC plant, created questionnaires outlining the issues that are often encountered by different RMC plants, and then posed these questions to various RMC plant staff members. By posing this query, we were able to analyse several characteristics and identify those that were crucial, such as site selection, resource management, supervision, and equipment.The site location, material handling, material management, and order processes all play crucial roles in the increase in productivity of the RMC plant and the achievement of large profit.In order to maintain this profit margin and increase customer happiness, this parameter must be effectively controlled. We can also draw the conclusion that in order to operate the RMC plant effectively, a checklist is needed at every stage. As a result, we must use construction management strategies in order to increase the plant's productivity.

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PG Student, Dept of Civil Engg, PVPIT, Bavdhan Pune