15 December 2018

Table of Contents for Readymix Concrete & Equipment

Readymix Concrete & Equipment

RMC’s Versatile Spectrum


A general wave of modernisation is currently sweeping India’s construction sector, which includes across the spectrum; from construction materials to construction equipment to construction methods. Within this, arrival of RMC has been rather late, only recent. While developed markets have already shifted to RMC as preferred material, Indian market is still struggling to adopt it. Characterised by low penetration, India remains a comparatively latent and untapped market.


Compared to global Standards, the usage of RMC in India constitutes only a miniscule percentage of the total concrete consumed in India annually. The actual start of commercial RMC in India can be assumed from 1994 and it has already taken nearly 20 years to achieve 8.5 per cent cement consumption. The growth of RMC industry in India last 3 to 4 years had been comparatively slow due to a general recession in Indian economy, which slowed down the construction sector, otherwise by now RMC could have achieved 10 per cent consumption of total cement produced in India. However, the real facilitator to opening up the RMC route in construction was the advent of conventional RMC agitated transit mixer trucks, which allowed the RMC to be transported to any project site. To disseminate widespread use of RMC in India, a techno-economic feasibility study for setting up of RMC plants in India was conducted by the Central Building Research Institute (CBRI), Roorkee, 1974. The study recommended setting up of RMC plants in major metropolitan towns of the country. It also suggested the use of fly ash as a partial replacement of cement to effect savings. In late 1970s, the then Cement Research Institute of India (CRI) – now National Council for Cement and Building Materials (NCB) – carried out a techno-economic viability study of RMC, to be transported without agitation. In this study, it was observed that the conventional RMC would be uneconomical under the then-prevailing conditions, wherein only small volumes of concrete (1 m3 or less) could be handled at a time, thereby making the transportation cost higher. To reduce the total cost, the study suggested that only a part of the mixing water (about 60 percent) be added at the central plant and such a “semi-dry” mix be transported in non-agitating trucks to the construction site, where the mix could be discharged from the truck to the mixer and remixed with the addition of the balance water.


This study further recommended that once the demand for RMC went up, conventional agitator trucks could be introduced, without any change in the central infrastructure. Based on this study, a feasibility report for setting up of RMC plant at Delhi was jointly prepared by the NCB and the Central Public Works Department (CPWD) in 1988.


As of last head count in 2012, based on the information obtained from various RMC manufacturers, there were about 2000 commercial plants in existence India adding up to a total capacity of 75000m3/hr. Currently, approximately 6 million m3 RMC per month (72 million m3 per year) is produced by commercial plants in India. The consumption of concrete in India during the year 2013-2014 is estimated at 460 million m3. Though no authentic figures are available, it can be assumed that nearly 15 per cent to 20 per cent concrete is being used by major mega projects where weigh-batched concrete through dedicated plants is used. The balance about 380 million m3 is used on medium, small and individual house building projects. If we consider the penetration of commercial RMC in this segment, then RMC has a miniscule share of about 18 per cent at present.


However, spurred by the demand generated for RMC by fast track roll out of EPC mega projects in the infra sector and government initiatives like “Housing for All by 2022” Mission – National Mission for Urban Housing and other initiatives like Affordable Housing, the demand for RMC is increasing gradually. An underlying common denominator of this RMC demand across all sectors is its ability to match the speed of construction projects which are executed under tight timelines. RMC has now emerged the material of choice due to its technical grade superiority, environmental sustainability and speed of application and is being used majorly across India, especially in its urban clusters where demand for housing is increasing exponentially. All these factors are opening up a very latent but huge market for RMC in India. But Quality and Standards still remain a problem and India is just beginning to achieve commercial grade of RMC.


In line with the traditional growth pattern of RMC world over, the expected potential of concrete in India and the progress made over the last 15 years, the growth of RMC in India will follow a path identical to the slow growth pattern followed RMC internationally. The 5.6 per cent consumption of cement through RMC in India was achieved within 12 years and 8.5 per cent within 17 years. Presuming better growth rate, the 10 per cent penetration may have been achieved in last 2 to 3 years till 2015. Based on above assumptions and fast mechanization of construction industry in India and numerous other favorable factors, the growth of commercial RMC in India is estimated as given in the above table.


The figures above are based on assumptions of; (a) the growth pattern was expected to accelerate after 2013, (b) The output of RMC plants would increase from present average of 3000 m3/month to 4000 m3/month over the years.





The biggest challenge currently for India’s RMC manufacturers is ensuring high quality of RMC manufactured and maintaining the consistency of that quality. In this context the Ready Mixed Concrete Manufacturers’ Association of India (RMCMA), has done a yeoman’s job, by introducing a Quality Control and RMC Plant Certification Scheme in India. It evolved a framework for quality for ready mixed concrete based on two strong pillars – Best Practices followed in advanced countries and adherence to provisions in the Indian standards. Two Quality Manuals prepared by an expert committee contain the details of the RMCMA Scheme. This plant audit-based scheme was launched in December 2008 and around 250 RMC facilities at 50-plus locations in India (mostly belonging to RMCMA member companies) were audited and certified by the RMCMA.


After operating this quality scheme successfully for nearly four years, RMCMA decided to raise it’s the quality scheme to a higher pedestal and signed an MoU with the Quality Council of India (QCI) for quality facilitation, accreditation and surveillance. QCI set up three committees; the Steering Committee, Technical Committee and Certification Committee. Experts from Multi Stakeholder organisations were invited to be the members of these committees. The involvement of these organisations in the evolution of the scheme ensured that the ownership is broad-based and comprises of representatives from major owners and specifiers in the country, using large volumes of RMC. The acceptance of RMC in India in the recent past is very telling. In a short span of time, RMC has made a place for itself throughout the country. People have become aware of it, people like it, people want to use it, people have a very favorable opinion about it and it is this changing mindset that will accelerate the future growth of RMC in India. There are numerous constraints in its growth at present but the overwhelming advantages the product offers will become sufficient reason to resolve the existing impasse. World over growth of RMC has followed ‘S’ curve and in India also, same pattern is emerging, may be with minor changes in the gradient of the curve. 


The RMC market in India is estimated to be worth $78.7 billion by 2024. Major demand drivers for RMC in India include power plants, transport (roads, railways, ports, airports), urban transport infra like elevated transport corridors and metro rail, where tight project time lines invite penalties for delays in project execution, which is fuelling demand for RMC in India. According to a report ‘Cement Vision 2025,’ published by the Confederation of Indian Industry-AT Kearny, about 60 per cent RMC market share is accounted for by the unorganised sector, where Quality and Certifications are a major issue. GST implementation will shift the market towards organised sector and RMC share in the overall cement market will likely grow from less than 10 per cent of total cement demand today to as high as 25 percent by 2025.




Achieving Commercial Grade: M20 (20MPa), M25, M30, M35, 60, 70 and 80 Mpa, 95 Mpa


Despite the fact that the first captive RMC plant was set in India in the 1950s, India failed to manufacture ‘commercial’ grade RMC for nearly five decades. Beginning in early 1990s India’s first commercial RMC facility was set up in Pune in 1992, which was quickly followed by setting up similar facilities at other locations across the country. Although no reliable data is available on the percentage of concrete production per strength class in India, a quick survey of concrete grades supplied by major RMC producers from metropolitan cities revealed that the dominant grade of concrete supplied by RMC (i.e. the minimum common grade used by a large number of RMC customers for structural use) is showing a moderate upward trend. While the dominant grade has increased from M20 (cube characteristic strength 20MPa) in 2003 to M25 in 2010 in Bangalore, Pune, Ahmadabad and Delhi, Chennai and Kolkata have graduated to the higher M30 grade, while Mumbai is even more higher at M35 grade.


With a rapidly mushrooming tall building population in urban India, the demand for High Strength Concrete (HSC) is increasing rapidly. For high-rise buildings applications, high-strength/high-performance concrete is the right kind of material. HSC provides the most economical way to carry the vertical load to the building foundation. By utilising HSC, column size, formwork size and the amount of vertical reinforcement can be reduced. Also, HSC allows early removal of shuttering works, reducing cycle time of the formwork. With an eye on these advantages, contractors were quick to adopt HSC RMC for rise buildings. In Mumbai, high-strength concretes having cube compressive strengths of 60, 70 and 80 Mpa have been supplied by some RMC producers and pumped at higher locations. HSC with cube compressive strength of 95 Mpa is being used for the World One tower currently being constructed by the Lodha Group.


Application of SCC, or Self-Compacting Concrete, in India commenced in early 2000. However its application remained confined to niche areas on a few projects, mainly by the Nuclear Power Corporation (NPC). In recent years, leading commercial RMC manufacturers have commenced supplying SCC for use in selective applications. However, here also, the use of SCC has remained confined to structures having heavily congested reinforcement or having innovative architectural shapes.


Key Players
  • ACC Limited
  • Chettinad Cements
  • Godrej Construction
  • Heidelberg
  • India Cements
  • India Cements
  • JK Lakshmi Cement
  • Larsen & Toubro
  • Madras Cements (Ramco Group)
  • Nuvoco Vistas Corp. Ltd
  • RDC Concrete
  • RMC Readymix (Division of Prism Cement Ltd)
  • Skyway RMC Plants
  • UltraTech Concrete




Advantage RMC
  • Uniform and assured quality of concrete, similar to a factory made product.
  • Higher durability and superior performance of structures built with RMC.
  • Faster construction speed.
  • Storage needs of raw materials at construction sites are eliminated.
  • Addition of admixtures and additives like fly ash, silica fume is easier.
  • Proper-documentation of the mix design are generated and stored for long periods.
  • Reduction in wastage of raw materials at construction sites.
  • RMC is eco-friendly and sustainable product.



RMCMA Prescribes

The Ready Mixed Concrete Manufacturers’ Association (RMCMA), India, has prescribed Standards at par with advanced countries. After in-depth study of prevailing quality systems in U.S.A., U.K., Canada, etc, RMCMA developed its self-regulatory framework to ensure consistent quality in RMC. It formed a Sub-Committee on Quality to draft a RMC Quality Scheme comprising two parts, ‘Quality Manual Part I and Part II, which were modified occasionally. Main quality parameters are workability, homogeneity, compactibility at pour site, 28-day compressive strength and long-term durability. The QC Plan should have the following elements:

Management of the quality of ingredients:

  • Sources/location of different materials
  • Crucial tests and testing frequencies for different ingredients for monitoring their quality

Process Control

  • Inspection and checking of different components of plant and other equipment and their frequency
  • Concrete mix design: Data on laboratory and plant trials

Sampling of concrete

Properties of fresh concrete

  • Data on slump, temperature, density,

Properties of hardened concrete

  • Data on compressive strengths of concrete at various ages; flexural strength (whenever specified)
  • Acceptance criteria
  • Standard deviation

Special QC techniques

  • Internal quality audit
  • Special techniques

Key personnel:

Internal quality audit Data pertaining qualification, experience and training of all personnel involved in production, quality control, marketing, etc.




“UltraTech RMC has been a preferred partner with major construction companies with our pan-India concrete and cement presence. Our relentless drive in providing consistent quality, high performance and reliable concrete is valued by our customers. Similarly, our technical support team and superior execution capabilities strengthen our relationship with key customers. We are the preferred partners in iconic projects in India like the metros, ports, bridges and highways. Our products like Free Flow, Thermocon, Décor, Colourcon and Pervious have found huge applications across India. In roads sector our White Topping Technology has been extensively used in Karnataka, Telangana and Maharashtra. We have also developed solutions for pothole repairs. In affordable housing segment our RMD Technology has been adopted by various state governments in South India. In other words, we make ‘Good Concrete Better’.”

Sanjay Mathur, CEO, RMC & Key Accounts, Ultratech Cement Ltd




“All our products are designed with long term applicability in mind. They are designed to have a higher service life than any of the other products offered in the market. ACC is a strong believer in sustainable solutions and this is the key pillar of thought while designing our concrete solutions. ACC is a part of LafargeHolcim Group (world leader in construction solutions) with which enables ACC to leverage technical support and global expertise on new technology in the field of construction. ACC has an established track record of consistently partnering with the biggest names in the country. It has a strong backup of a world class research centre at Lyon, thus ensuring best-in-class solutions, making it the leading choice when it comes to construction solutions. ”

 Anil Kulkarni, Head - Sales & Operations, ACC Readymix Concrete




“RDC Concrete has a robust fleet management system and most efficient distribution and supply chain management in the industry. All transit mixers and concrete pumps are GPS enabled for real time tracking, effective supply, and better customer satisfaction.

We are now offering crack-free concrete, exclusively developed by RDC’s R&D team for our customers. We are planning to come up with dry and wet concrete bags to address small repair works requirements. They will satisfy need of quality concrete in remote locations and inaccessible construction sites.”

Anil Banchhor, MD & CEO, RDC Concrete (India) Pvt Ltd,







RMC Equipment Completes RMC Ecology


RMC equipment is an excellent example of smart technology in process equipment.


Especially the batching plants which use SCADA (Supervisory Control Data Acquisition), PLC (Programmable Logic Control), Calibration, etc. The very nature of the product requires a set of machinery in sequence due to its perishable nature. The need to achieve consistency of the required RMC grade can only be met with a proper batching plant to get the correct mix of raw material ingredients. Once that’s achieved it becomes just as critical to deliver it in a transit mixer to the project site where speed is of importance, and finally the pump and placement booms have to pour the RMC at the project site. The biggest challenge for pumps is to ensure pouring the RMC without it getting clogged. Most manufacturers of RMC equipment are tied up with major RMC manufacturers and supply equipment for their turnkey projects onsite. This is basically because RMC is more of a service industry where the material supplier and equipment supplier have to coordinate to ensure timely pouring at the site, due to the perishable and quick setting nature of RMC.


As in other construction equipment verticals, India boasts some major global brands in the RMC equipment sector. Broadly, the three major segments in concreting equipment include Concrete Batching Plants, Concrete Transit Mixer Trucks, and Concreting Pumps. As late entrants in the market, Indian RMC manufacturers have the advantage of using latest-generation plant and equipment for their plants with sophisticated micro-processor based controls having ability of accurate weighing and batching, automatic charging, adjustments for moisture compensation and inventory control. Most of them also have a fleet of transit mixers of various capacities and are also well-equipped with facilities for pumping concrete. Most brands offer RMC equipment in various types and capacities, and leading brands offer high-end equipment loaded with Smart features. German majors Putzmeister and Schwing Stetter, Chinese global major Sany, are among the leading global brands here and among the few companies who offer an integrated portfolio of RMC equipment comprising batching plants, transit mixer trucks, and concreting boom pumps. Other players include; Ajax Fiori, Universal Construction Machinery & Equipment, Apollo Infratech, Aquarius Engineers, Ready Mix Construction Machinery Pvt. Ltd. (RMX), etc.


Putzmeister Concrete Machines, offers batching plants, concrete pumps and placing systems. The company has introduced one of its globally most renowned mortar equipments to India, namely the P 13, MP 25, S5 and Mixokret. Putzmeister’s most notable product is the PUMI® which combines pump, mixer, and placing boom in a single machine. It is an addition to the fleet of truck-mixers held by service and customer oriented suppliers of ready-mixed concrete and significantly extends the range of jobs they can take on: a PUMI® is particularly economic wherever truck-mounted concrete pumps are too expensive or too big and inflexible or wherever truck-mixer conveyor belts are not adequate. In particular, it can be operated cheaply and quickly in small construction sites up to approximately 20 m3.


The company is also active in skill development in the RMC space. Putzmeister conducts courses for “Recognition of Prior Learning” (RPL) where concrete pump operators are trained and assessed to work with the machines. RPL is a part of Pradhan Mantri Kaushal Vikas Yojana (PMKVY) an initiative by the Infrastructure and Equipment Skill Council (IESC) and Skill India. Putzmeister aims to conduct more RPL trainings for concrete pump operators as they lead to significant advantages – for the operators as well as for Putzmeister.



The first batch has successfully completed the RPL course in December 2016: Nine candidates underwent four days of mandatory training in Mumbai. Training topics included comprehensive operation, maintenance, and safety, of Putzmeister’s BSA Stationary Concrete Pumps. The final assessment consists of a questionnaire in English, One-on-one tests and a practical demo on the machines. In the end, the candidates receive an official certificate authorised by Putzmeister.


Putzmeister is also well known for setting concreting records. It set a new vertical concrete pumping record of 740 feet (225m) in Mexico using a single trailer pump – the Putzmeister BSA 2109. The “standard” unit pumped over 19,000 cubic yards (14,612m3) to this height during the construction of 55-story tower Torre Mayor, Mexico City’s premier corporate Tower. It has also set several other records in the GCC Gulf countries which have a fast mushrooming tower population using RMC.


Incidentally, Putzmeister was acquired by Sany to complete their portfolio of concreting equipment, and construction equipment in general. However, the brand enjoys considerable independence from the parent company in its global operations.


Sany recently launched a Batching plant BP HZS120,Transit Mixers STM7 and STM8. The company offers a range of truck-mounted concrete pump, trailer pump, line pump, placing boom, transit truck mixer, batching plants etc, in the RMC space. Despite being a relatively late entrant in India, the company has significant inroads in the Indian market.


Schwing Stetter, global major from Germany offers batching plants, concrete pumps, and truck mixers. Its Smart batching plants come in small medium and big capacity, features include SCADA and advanced control systems. In their transit mixers, most notable is the Nimo-- the anytime, anywhere mixer is a revolutionary product, it is the only mixer which is permitted to transport concrete during daytime, something crucially important for executing projects in crowded urban areas. Schwing Stetter is also a regular record setter in the RMC space.


In April last year, the Schwing Stetter Operator Training School was awarded and certified as the First Training Centre to certify pump operators under the Pradhan Mantri Kaushal Vikas Yojana Initiative Scheme in India. The company has also partnered with the IESC to start the first “Centre of Excellence” in India, where in construction equipment operators will receive a certified degree from the IESC for skilling of equipment operation and maintenance.


Ajax Fiori celebrating its 25th anniversary is a leader in Concreting Equipment in the Indian market and is a global leader in SLCM segment. The company is setting up a new plant in Doddaballapur to meet the increasing demand. Ajax recently launched Argo 2500 SLCM 120 Cu.m/hr Batching Plants, 70 cu.m/hr Concrete Pumps and soon entering 6, 8, 10, cu.m Mixer. Its Compact Reduced Bin Batching Plant (CRB) of 30 cu.m/hr. capacity was designed especially for the RMC segment.


Universal Construction Machinery & Equipment, is a global major from India playing in most regional markets across the world. It manufacturers products across the concreting equipment spectrum, including: Concrete Mixer; Batching Plant; Concrete Pump; Boom Placer; Transit Mixer; Self Loading Mixer. It also has business collaboration with Chinese global major Zoomlion, for distribution and marketing, and sales and service, of their concrete pumps in India. It recently launched ‘Universal Heavy Engineering Division’ to cater to increasing demand for higher capacity concrete batching and mixing plants (45 cum/hr. to 240 cum/hr. capacity), matching the accelerating speed of Infrastructure development at a faster pace. The Division will use latest Production Processes and Quality Controls, confirming to International Standards. The Division has been allocated 15 Acres at its 37 acres Shivare site, Near Pune. The plant will have German and Japanese Robotic Welding Systems, to ensure highest level of welding quality which is comparable with any top international manufacturer, and its R&D uses latest design software for designing the larger capacity concrete batching and mixing plants. It also has latest Quality Control Equipment/Instruments to achieve the highest Quality as per International norms. Its simplified Batching and Mixing Plants ensure cost benefits in the longer run.


Apollo Inffratech offers RMC batching plants in varying capacities and transit mixers. It has a joint venture with Italian major, Carmix, a leader in manufacturing Self Loading Concrete Mixer, known as Apollo Carmix Equipments Private Limited(ACEPL). The company is equipped with modern factory setup and design development facilities to produce high quality concrete construction equipment.


Aquarius Engineers offers concrete boom pumps, concrete line pumps, and batching plants, in stationary, truck mounted and mobile versions. The company is working in partnership with ACC as turnkey project supplier. India’s RMC ecology is yet to mature, leaving plenty of room for growth. Both, RMC and RMC equipment manufacturers are developing products in tandem. While cement manufacturers are offering branded RMC products of different grades as per applications, equipment manufacturers are developing products across verticals ranging from batching plants to pumps. Major demand drivers for RMC and RMC equipment include the infra sector across the power, transport, and urban infra verticals. The use of RMC as the preferred method and preferred construction material is gaining recognition to the extent that most government contracts for mega projects stipulate the use RMC in their construction. Overall, the RMC market in India, though still latent, is poised to grow rapidly over next few years. Other major demand driver for RMC in India is the real estate sector.




“Schwing Stetter India provides after sales service and spares from its branches located across the country, through its 29 spares stores and 9 service centers. Its well trained resident service engineers are available near jobsite clusters at Hubli, Trichy, Madurai, Nellore, Goa, Nasik, Bhopal, Jabalpur, Siliguri, Uttarakhand, Rajkot, Dahej and many more. The service centre also offers services like overhauling of all range of equipment from minor to major, periodic maintenance, conversion, mounting, insurance handling, retro fitment, repainting of equipment, and much more. Our company also offers annual maintenance contract, operation and maintenance packages, turnkey projects, re-erection and commissioning of batching plants. We also buy back old machines, upgrade them and resell with limited warranty; these used machines are also sold to new upcoming customers.”

V.G.Sakthikumar, MD, Schwing Stetter Sales And Services



“Our plastering machine MP 25 has proven to have the potential to set new standards in the Indian construction industry. Reliable and compact, the MP 25 is ideal for conveying and spraying gypsum and premixed dry mortars at high speeds of up to 40 litres per minute. Compared to manual labour, it has zero wastage of unused material due to no rebound. This machine gets a tough job done, in a fast, economical, and clean way.”

Wilfried Theissen, MD,  Putzmeister Concrete Machines




“Universal is offering a wide range of concrete batching plants from capacity 15 cum/hr. upto 240 cum/hr. We are offering the various types of batching plants like mobile batching plants fitted on a trailer, skid mounted batching plants, stationary batching plants. These batching plants are supplied with different options for aggregate feeding systems, different types of mixers, and controls. In case of higher capacity batching plants we offer customized solutions. Universal has adopted robotic welding technology which ensures highest level of Quality compared to other plants available in the market. The production processes adopted by Universal ensures accurate batching and also ensures longer life cycle of the equipment. ”

Rajesh Kawoor, SR. Vice President, Universal Heavy Engineering Division, Universal Construction Machinery & Equipment Ltd.



“In India we have transit mixers and batching plants manufacturing in our state-of-the-art Pune plant. Currently we have 6 to 8 cubic meter transit mixers. Batching plants we have from 30 cubic meters up to 360 cubic meter/hr capacities. We offer complete range of RMC equipment from RMC manufacturing, transporting, and placing solutions.”

C.R Jyothiraj, General Manager (Concrete Equipment Business) Sany (India)



“Apart from our product range expansion, we have increased our distribution network and have over 80 touch points pan India. We are setting up our new plant in Doddaballapur which is a line production facility. This new facility will help us add capacity and enhance our product portfolio to serve our customers need in future. This facility not only supports our commitment to India’s economy but it also presents a significant opportunity for our strong growth in India. Having foreseen the product’s sustainability across various applications and the increased demand across geographies, Ajax Fiori has ambitions to create a significant presence beyond Indian shores in the coming years.”

Jagadish Bhat, CEO, Ajax Fiori Engineering India



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