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Quality Manual of RMC- Part I

Certification of

Ready-Mixed Concrete Production Facilities

Check List(Sixth revision, Feb 2008)

Ready Mixed Concrete Manufacturers Association, IndiaB-5, Ground Floor, Neel Shantiniketan Co-op. Housing Society, Manipada Road,

Opp. Mumbai University,Kalina, Santacruz (E), Mumbai 400 098,Tel.: 91-22-26654165, E-mail: [email protected] Web: rmcmaindia.org

Formatted: Italian (Italy)

mailto:[email protected]

mailto:[email protected]



1

INDEX

1. Preface 2

2. Acknowledgement 4

3. Expert Committee/Sub-committee members 5

4. Audit Procedures 6

5. Table 1: General Information of Ready

Mixed Concrete Facility 8

6. Table 2: General Information on

Concrete Production Facilities 9

7. Table 3: General Information

on Material Handling 10

8. Check List

Material Storage and Handling 11

Batching Equipment 15

Central Mixer 30

Ticketing System 31

Delivery Fleet Inspection 33

Laboratory Facilities 36

7. References 39

8. Notes 40



2

Preface

The concrete industry scenario in India has witnessed significant changes in the past

decade. Although concrete construction has traditionally been a labour-intensive activity,rapid economic growth with emphasis on the development of physical infrastructure ledto an increase in the demand for higher speed and improved quality of concreteconstruction for residential and commercial housing, flyovers, roads, etc., especially in

metropolitan and other big cities of the country. This necessitated increasing adoption of mechanized and semi-mechanized techniques of construction, which needed large

volumes of quality concrete, produced and placed speedily. This was conducive to thedevelopment and growth of ready-mixed concrete in India.

The first commercial RMC facility in India was set up in Pune in 1992 and was followed by establishment of similar facilities in Mumbai, Bangalore, Chennai, Delhi, and other places. After overcoming the initial teething troubles, the industry witnessed steady

growth, mainly in the urban area. It is estimated that in 2006-07, India producedapproximately 15-18 million m3

of ready-mixed concrete from around 350-400 RMCfacilities and the number has been growing continuously. Yet, the percentage of cementutilized through RMC route is meager — less than 5 % of the total cement produced inIndia. Thus, the prospects for growth are good. This is both a challenge and an

opportunity for the industry.

The spread of RMC facilities in urban India has brought in its wake certain challenges.

Since RMC is not a finished product and the quality of the final product is dependentupon a host of factors― some of which are beyond the control of the RMC producers― there is likelihood of a variation in the uniformity and quality of the final product. Yet,

the customer needs to be provided with some sort of assurance about the quality of the

concrete supplied. This highlights the need of developing a framework of quality schemefor RMC.

The Ready Mixed Concrete Manufacturers’ Association (RMCMA), India, which wasestablished in March 2002 and has been striving hard to bring the Indian RMC industry at

par with the industries in advanced countries, has taken up this challenge. After an in-depth study of the prevailing quality systems in different parts of world, the RMCMA has

decided to develop a self-regulatory framework of Quality Scheme involving certificationof RMC plants based on the third-party audit conducted on the basis the Check List of Production Facilities. The RMCMA formed a Sub-Committee of experienced quality personnel from member companies and this group was assigned with the task of

preparing a Check List of Production Facilities. After the draft Check List was prepared,various items were thoroughly discussed and numerous modifications were made in the

list. Further, the RMCMA established a National Experts Committee and based on theguidance of the committee, certain modifications were made in the regulatory framework.



3

In addition, a number of mock audits based on the Check List were carried out, resultinginto further refinement of the Check List.

While developing the Check List, it was ensured that the provisions in the same meetmost of the stipulations in the Indian Standard on Ready Mixed Concrete, IS 49263

(second revision) and the other relevant codes on concrete such as IS 4561, IS 9103

2and

many others. In fact, the requirements of the Check List, in some cases, exceed those of

the codes. Thus, RMCMA certification through a third-party audit would provideassurance to the user that the production facilities of the certified plant conform to therequirements of the IS code.

However, it needs to be pointed out that availability of proper equipment is only one of the factors — although a very vital one — that controls quality of concrete. No claim is

made that certification of RMCMA will necessarily assure delivery of high qualityconcrete. The RMCMA certificate should therefore be accepted precisely for what it is — evidence that a certified production facility do possess capabilities to produce quality

concrete. The existence of these capabilities will reduce the likelihood of deficiencies inquality of final product.

In addition to third-party audit of production facilities, it was felt that this needs to be

supplemented by data on process control and properties of concrete and its ingredients.This could best be done by preparing a QA-QC Document by each RMC facility. For providing guidance in this respect, RMCMA has prepared QC Manual Part-II

“Guidelines on Quality Control & Quality Assurance of Concrete”. It is recommended

that each RMC facility should prepare its own QC Manual following the minimum benchmarks suggested in this document. Such document, which incidentally needsconstant updating, would demonstrate RMC producer’s commitment to quality concrete.

While successful clearance from third-party annual audit is mandatory for obtainingRMCMA certification, similar audits based on the guidelines suggested in QC Manual

Part-II would not be possible and hence not proposed.

RMCMA is indebted to the National Experts Committee and its Sub-Committee on

Quality for evolving the self-regulatory framework. We strongly believe that the self-regulatory quality framework initiated by RMCMA would go a long way in providing

assurance to the customers about the quality of concrete.

(Vijay R Kulkarni)

Principal Consultant, RMCMA



4

Acknowledgement

We are grateful to each member of the RMCMA’s Sub-Committee on Quality for

carefully scrutinizing different provisions in the document. The provisions were

thoroughly discussed in the meetings of the Sub-Committee and several modifications

were made after reaching broad consensus. The help rendered by Sub-Committee

members is highly appreciated and we are thankful to them for their involvement and

efforts.

We are also indebted to all members of the National Experts Committee who have

provided broad guidance on different aspects of the provisions. They not only carefully

scrutinized the provisions in the Manuals but also helped the RMCMA in finalizing itsapproach to the Quality Scheme by offering valuable suggestions. The RMCMA would

like to record its deep sense of gratitude towards the members of the Experts Committee

for their valuable guidance.

(Vijay R Kulkarni)

Principal Consultant, RMCMA



5

Members of National Experts Committee

• Dr. A. Ramakrishna- Advisor, Larsen & Toubro Ltd.

• Dr C. S. Viswanatha, Torsteel Research Foundation in India, Bangalore

• Mr. Jose Kurian- Chief Engineer, DT & TDC, New Delhi

• Mr. A. K. Jain- Technical Advisor, Grasim/ UltraTech

• Mr. P L Bongirwar- Former Dy. M.D., MSRDC, Mumbai

• Mr. C M Dordi- Vice- President ( Tech Services), Gujrat Ambuja

Members of RMCMA’s Sub-Committee on Quality

• Dr. P. Dinakar, ACC Ltd

• Mr. Harpal Singh Sehmi, ACC Ltd

• Mr. Anuj Maheshwari- Grasim Industries

• Mr. S. G. Bhat, Larsen & Toubro Ltd

• Mr. Hiren Joshi., Larsen & Toubro Ltd

• Mr. S. D. Govilkar, RMC Readymix (I) Pvt Ltd.

• Mr. Girish Bonde, RDC Concrete

• Mr. Awadhoot Sawant- Godrej & Boyce

• Mr. Bilal Baig, Godrej & Boyce



6

Audit Procedure for obtaining Certification

The broad steps involved in third-party audit are listed below.

1. Member of RMCMA or a producer intending to be a member approaches

RMCMA in writing for Certification of his particular production facilities.

2. The RMCMA replies back quickly requesting the RMC producer to furnishinformation about his production facilities in a standard format.(Tables 1, 2

and 3)

3. The RMCMA studies the inputs from producer and if the production facilitiesfulfill all statutory requirements (Table 1), includes their name in the list of

facilities to be audited. The RMCMA also assigns priority on first-come-first basis.

4. The RMC producer deposits the requisite fees of audit with the RMCMA.

5. RMCMA selects trained auditor from its own accredited pool of auditors anddirects him/her to undertake the audit of the said production facilities.

6. Auditor gives an undertaking stating that he has no business relationship at

personal level with the RMC producer, whose plant he would be auditing. He

also declares that he would abide by the provisions of the Check List.

7. The auditor audits the production facilities in accordance with the Check Listof RMCMA.

8. Any shortcoming in the facility is informed to the RMCMA in writing. The

producer is requested by RMCMA to rectify the shortcoming within a periodof two months.

9. The auditor revisits the RMC producer’s facility and satisfies himself/herself

about the rectifications made by the producer.

10. Once the auditor is satisfied that the all the necessary provisions in the facilityare in accordance with Check List, he/she puts his/her dated signature and

stamp on each page of the Check List.

11. The RMC producer simultaneously signs an undertaking stating that he wouldabide by the provisions in the Check List during the period of certification.

12. Once the RMCMA receives the duly signed Check List from the auditor andthe undertaking from the producer, certification is granted to the RMC

producer’s facility, after formal approval from the Managing Committee of RMCMA.

13. During the period of certification, any purchaser can verify as to whether the

provisions in the production facility are as per the certified Check List.

14. Before the expiry of certification, the producer will approach RMCMA for the

fresh audit of his facility.

15. Complaints: RMCMA would entertain complaints on failure to adhere to therequirements of the Check List. Any complaint in respect of product quality,



7

particularly shortcomings in achieving the fresh and hardened properties of concrete are not covered under the certification as this would be a part of the

contractual agreement between the RMC producer and his clinet.

16. In case the complaint provides information on specific non-performance of items in the Check List, the RMCMA would seek report from the auditor who

inspected the production facilities. Both the complaint and the auditor’s reportwould be placed before the National Committee of Experts and the Managing

Committee of RMCMA. If it is fond that the auditor did not conduct theinspection audit properly, he/she would be warned and may also loose theaccreditation to be RMCMA’s auditor.

17. If the complaint pertains to the failure on the part of the RMC producer tomaintain production facilities as per the Check List, the producer would beinformed accordingly and would be given a time of one month to rectify the

errors. Auditor would then visit the facility to verify whether the rectificationsare carried out and send report to the RMCMA. If the rectifications are not

carried out in the stipulated time, the RMCMA Committees may revoke thecertification of the facility.



8

Table 1: General Information of Ready Mixed Concrete Facility

Company Name

Company Address(Register office)

Tel.Fax

e-mail

Location of Plant

Address of Plant

Tel.Fax

e-mail

Personnel information

• Plant-in-charge/Manager

• QC personnel

• Liaison personnel

NameTelephone

NameTelephone

NameTelephone

Material Testing

Facilities

Location and address

Name of lab in-charge

TelephoneStatutory Permissions* Certificate from Pollution Control Board

Yes No

Expiry date:

Approval from factory inspector

Yes No

Expiry date:

Approval from Local Authorities (Municipal/Corporation)

Yes No

Expiry date:

* It is essential to attach photocopies of all relevant statutory permissions andcertificates.



9

Table 2: General Information on Concrete Production Facilities

Name of Plant Manufacturer

Type of Plant

Plant’s Rated capacity, m3/hour

Type of Mixer* Rotating-drum type Power mixer

Pan type , Pan-type with agitator

Single shaft , Twin shaft

Mixture batch size, m3

Storage Capacity

Cement, tonnes

Fly ash, tonnes

Slag, tonnes

Other cementitous material, tonnes

Coarse aggregates, tonnes

10-mm

20-mm

40-mmFine aggregates, tonnes

River sand

Manufactured sand

Crusher fines, tonnes

Water, litres

Chemical admixtures, litres

Plasticiser

Superplasticiser

Retarder

Any other

Others

Brief description of recycling facility, if any

Number of trucks with rated capacities

Name of drum and truck manufacturer 1

2

3

Additional information on Plant and Trucks,

if any

* Tick (√ ) in appropriate box.



10

Table 3: General Information on Material Handling

Material Delivery to

Plant

Storage Storage to Mixer

Cement Bulk

Bags

Silo

Bins

Godown

Screw conveyor

Coarse aggregates Trucks Star pattern

In-line bins

compartments

Tall/pocket silos

Conveyor

Skip bucket

Bucket conveyor

Fine aggregates Trucks Star pattern

In-line bins

compartments

Tall/pocket silos

Conveyor

Skip bucket

Bucket conveyor

Fly ash Bulk

Bags

Silo

Bins

Screw conveyor

Manual

Slag Bulk

Bags

Silo

Bins

Screw conveyor

Manual

Micro silica Bags Silo

Bags

Screw conveyor

Manual

Other cementitiousmaterial (specify)

Bags Silo

Bags

Screw conveyor

Manual

Water Mun. mains

Wells

Ponds

Underground/over-

ground tank

Municipal Mains

Pumping/gravity flow

through pipe network

Chemical admixtures Drums

Tankers

Drums

Tanks

Dispenser

Special arrangementfor supplyingtemperature-controlled

concrete, if used

Use:

Occasional use Not used

Arrangement

1. Addition of ice slabs in mixing water tank

2. Addition of ice flakes in mixing drum

3. Chilling Plant

4. Combination of above (1/2/3)

* Tick (√ ) in appropriate box. If materials/ provisions not used, keep the boxes blank.



11

Check List1.0 MATERIAL STORAGE AND HANDLING

1.1 CEMENTITIOUS MATERIALS

1.1.1 Cement 1.1.1.1. Are silos/bins and the cement feeding area weatherproof?

Yes

No

1.1.1.2. When cement is supplied in bags, is the storage facility weatherproof, damp-

proof, well ventilated and reasonably free from dust?Yes

No N.A.

1.1.1.3. When cement is supplied in bulk, is there reasonably dust-free flow of cement

into silo and further from silo to the mixer, indicating thereby that the loading and

handling system permits free flow and efficient discharge of cement??Yes

No N.A.

1.1.1.4. When cement is supplied in bags, does the bag splitting unit and pneumatic pump/vertical screw conveyor permit reasonably dust-free flow - of cement into silos and

further from silo to the mixer?

Yes No N.A.

1.1.1.5. Where storage is provided for different types of cement, is the storage of bagssufficiently isolated to prevent intermingling or contamination?

Yes No

N.A. 1.1.1.6. Are there sign boards to indicate storage of different types of cement?

Yes

No

1.1.2. Supplementary Cementitious Materials (SCMs))

1.1.2.1. Is there a separate storage system for different types of SCMs?Yes No

N.A.



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1.1.2.2. If more than one SCM is being used, is there is a separate storage system for different types of SCMs?

Yes No N.A.

1.1.2.3. Are silo/bag storage system for SCMs weatherproof?

Yes No N.A.

1.1.2.4. Is the SCM loading and handling system permitting reasonably dust-free flow of the material into silos and then further from silos to the mixer?

Yes

No N.A.

1.1.2.5. Are there sign boards to indicate storage of different types of cementitious

materials?Yes

No

1.1.3. Aggregates

1.1.3.1. Are there adequate provisions for separate storage for each size and type of aggregates so as to prevent mixing of different sizes and types?

Yes No

1.1.3.2. Are there sign boards to indicate different sizes of aggregates? Yes No

1.1.3.3. Are adequate precautions taken during unloading and building of stockpiles of aggregates so as to prevent harmful segregation and breakage?

Yes

No

1.1.3.4. Are adequate precautions taken to prevent intermixing of aggregates with dust,

mud, soil and other deleterious materials?Yes No

1.1.3.5. Are adequate precautions taken to prevent contamination of different sizes and

types of aggregates with each other?Yes No



13

1.1.3.6. Are the aggregate storage bins and conveyance systems adequately covered toavoid direct exposure to Sun, rain, or snow, etc?

Yes No

1.1.3.7. Is there a provision of water sprinklers or other system (fog system) to bring

down the temperature of aggregates in hot weather?Water sprinkler

Other system (specify) N.A.

1.1.3.8. Is the water sprinkler/other system effectively maintained and used in practice? Yes No

1.1.4. Water

1.1.4.1. Is there adequate storage of water to satisfy the day-to-day needs?

Yes No

1.1.4.2. Has the water storage facility been protected to minimize the risk of

contamination of deleterious substances?Yes No

1.1.4.3. If recycled water is used in the production of concrete, are adequate precautionstaken to ensure that the overall limits on chloride/sulphate content, suspended particles, pH are not exceeding those given IS 4561?

Yes No N.A.

1.1.5. Chemical Admixtures

1.1.5.1. Are chemical admixtures stored properly to avoid contamination and degradation

on exposure to direct sunlight?Yes No

1.1.5.2. Is there a provision for providing agitation to liquid admixtures that are not stablesolutions?

Yes (Manually)

Yes (Mechanically) No N.A*. * (Not needed as per manufacturer’s instructions)



14

1.1.5.3. Is the storage and handling system adequately protected to prevent freezing of admixtures during winter season?

Yes No N.A.

1.1.5.4. Are adequate precautions taken to use admixtures before expiry date?Yes

No 1.1.5.5. Does each container of admixture legibly marked with supplier’s information asgiven in Clause 10.1 of IS 91032?

Yes No N.A.

1.1.5.6. If supplied in tanks, has the admixture manufacturer given information as givenin Clause 10.1 of IS 91032? Is such information readily available with the RMC facility?

Yes

No N.A.

1.1.5.7. Does additional printed information provided by supplier as per clause 10.2 of IS9103

2available with the RMC facility?

Yes No



15

2. BATCHING and MIXING CONTROL EQUIPMENT

There has been considerable technological advancement in batching equipment. For

the sake of convenience and easy identification, the Check List of batching

equipment is divided into two broad categories, namely, Latest-generation Batching

and Mixing Control Equipment and Old-generation Batching and Mixing Control

Equipment. The former category mainly comprises of: micro-processor-based load

cell for ensuring accuracy in weighing system, accurate admixture dosing system,efficient power mixer for assuring efficient blending of cementitious materials, and

computerised control of the entire batching, mixing and delivery ticketing processes.

All these features are essential for categorising the plants to be Latest-generation

Batching and Mixing Control Equipments. Plants lacking in any of these features

would be categorised as Old-generation Batching and Mixing Control Equipment.

Depending upon the facilities available, the auditor can choose the Check List items

either in 2-A or 2-B category. He/she cannot use selective items from both the

categories simultaneously.

2-A. LATEST-GENERATION BATCHING AND MIXING CONTROL

EQUIPMENTS

2-A.1. SCALES

2-A.1.1Each scale comprised of a suitable system of load cells which will weigh

consistently with loads indicated by means of a digital read-out or display. For all typesof batching systems, is the batch operator able to read the load indicating devices fromhis normal station?

Yes

No 2-A.1.2. Have the preset controls been calibrated in increments not exceeding 5 kg or lesseach for cement and mineral admixtures, 10 kg or less for aggregates and 2 kg or less for

water? (Clause E-1 (c) of Annex E of IS 49263)

Yes No

2-A.1.3. For continuous mixer plants, has the calibration been done in increments notexceeding 10 kg/m3 each for cement and mineral admixtures, 25 kg/m3 for aggregatesand 10 lit/m3 for water? (Clause E-1 (d) of Annex E of IS 49263)

Yes No

2-A.1.4. Do the digital read-outs have a scale increment not exceeding 2 kg eachfor cement and mineral admixtures, 10 kg for aggregate and 1 litre for water? (Clause E-1

(e) of Annex E of IS 49263)Yes No



16

2-A.1.5. Does the records show that at east 1000 kg of suitable calibrated and stampedtest weights have been used for checking accuracy of scales.

Yes No

2-A.1.6. Does a systematic recheck of scales carried out frequently (at least once every 3

months for electrical load cell system)? (Clause E-1 (j) of Annex E of IS 49263)

Yes

No 2-A.1.7. Is prompt recalibration done and correction carried out if the plant is moved or non-compliance is indicated in the 3-month rechecking?

Yes

No N.A.

2-A.1.8. Is a systematic record of calibration of weighing and measuring systemavailable?

Yes

No

2-A.1.9. Are adequate permanent facilities provided for the application of test

weights to the weighing hopper or system? (Clause E-1 (j) of Annex E of IS 49263).

[These facilities may consist of anchor /suspension points, or trays, or platform, or hangers or other equipment as required.]

Yes

No 2-A.1.10. Have the load-cell scales been arranged to transmit load to one or more cells,directly in such a way that the cell system registers the entire load accurately on the load-indicating device?

Yes

No

2-A.1.11. Have the load cells been protected to avoid ingress of moisture?

Yes

No N.A. (in-built system)

2-A.1.12. Are the personnel involved in the work of calibration of weighing equipmentscompetent and fully trained? (Clause E-1 (p) of Annex E of IS 49263)

Yes No

2-A.2. WEIGH BATCHERS (Clause 9.1.2 and 9.1.3 of IS 49263)

2-A.2.1. Have the hoppers for weighing cement, aggregates, and also water andadmixtures (if measured by weight) consist of suitable containers freely suspended from ascale, and are they equipped with necessary charging and discharging mechanisms?

Yes

No



17

2-A.2.2. Are the scales and weigh hoppers used for cement and other cementitiousmaterials independent of scales and weigh hoppers used for non-cementitious

ingredients?Yes No

2-A.2.3. In cumulative weighing of cementitious materials, is the Portland cementweighed before the supplementary cementitious materials?

Yes No

2-A.2.4. Are the hoppers capable of receiving maximum rated load without contact of the

weighed material with the charging mechanism?Yes No

2-A.2.5. Are cement batchers provided with dust seal between charging mechanism andhopper, installed in such a way as not to affect weighing accuracy?

Yes

No 2-A.2.6. Are weigh hoppers vented to permit escape of air without emission of cement

dust?Yes

No 2-A.2.7. Are hoppers self-cleaning and fitted with means to assure complete discharge?

Yes No

2-A.2.8. Is the hopper charging mechanism capable of stopping flow of material within batching tolerances specified in para 2-A.5.1 and preventing loss of material whenclosed?

Yes No

2-A.2.9. Are vibrators or other equipment installed in such a way as not to affectaccuracy of weighing?

Yes No

N.A. 2-A.2.10. Is wind/weather protection sufficient to prevent interference with weighingaccuracy?

Yes No

N.A.



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2-A.3. BATCHING DEVICES FOR WATER

2-A.3.1. Water is measured by:Volume Weight

2-A.3.2. Are water meters/weigh batchers equipped with a cut-off device capable of stopping the flow within the tolerances specified in 2-A.5.1?

Yes No

2-A.3.3. Is cutoff device free from leaks when closed?

Yes No

2-A.3.4. If measured volumetrically, are water meters equipped with a volume-settingdevice capable of being set to increments at least as small as 5 litres or a register capable

of being read to, 5 litres or both?Yes No

N.A.

2-A.3.5. Is the system capable of providing an indication, visible to the batch operator , of the volume/weight batched at any point in the metering/weighing operation?

Yes

No

2-A.4. DISPENSERS FOR LIQUID ADMIXTURES (Clause 9.1.2 and 9.1.3 of IS

49263)

Chemical admixtures (either by weight or volume) shall be added to the concrete mixture

with the help of a dispenser — a device for batching of liquid admixtures. Admixtures

shall not be administered with manual method.

2-A.4.1. Liquid admixtures are measured by:

Volume Weight

2-A.4.2. Is there a separate dispenser for each liquid admixture in regular use?Yes

No 2-A.4.3. If more than one admixture is being used through a single dispenser without

flushing of the dispenser with water after each cycle, do the plant personnel ascertain thatthe admixtures in actual use are compatible with each other and that the mixing of admixtures prior to introduction in to the concrete is not detrimental?

Yes No N.A.



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2-A.4.4. When using a single dispenser, if the admixtures are not compatible with eachother, is the dispenser flushed with water after each cycle?

Yes No N.A.

2-A.4.5. Are the pipes carrying admixture free from leakage and are they properly calvedto prevent backflow or siphoning so as to ensure that the measured amount is discharged?

Yes No

2-A.4.6. Is each dispenser of liquid admixture provided with an accurately calibratedcontainer (if measured by volume) in which the admixture can be collected when it isdesired to check the accuracy of measurement as indicated in 2-A.5.1?

Yes No N.A.

2-A.4.7. Do the admixture dispensers have scale increments which enable materials to be batched within a tolerance of 3% of the scale reading?

Yes No

2-A.4.8. Do dispensers of liquid admixtures provide visible indication of thequantity batched or interlock cut-off when liquid admixture supply is not available to thedispenser? (This is to prevent dispensing air instead of admixture).

Yes

No N.A.

2-A.5. ACCURACY OF PLANT BATCHING (Clause E-1 of Annex E of IS 49263)

{Note: For weighed ingredients, accuracy of batching shall be determined by comparison

between the desired weight (as indicated by the batch operator and corrected for aggregate moisture, if required) and the actual scale reading.}



20

2-A.5.1. The accuracy, sensitivity and arrangement of weighing devices shall be such asto enable the materials to be batched within the following tolerances:

Cement and mineral admixtures: Within ± 2 percent of the quantity of constituents being measured

Yes No

Aggregate, chemical admixture and water : Within ± 3 percent of the quantity of constituent being measured

Yes

No 2-A.5.2. Is there an appropriate system of finding aggregate moisture either manually or automatically to provide aggregate of fairly consistent moisture content to the batcher and

to detect changes of 1 percent in the moisture content of aggregate?Yes No

2-A.5.3. Are appropriate procedures followed for adjustment of aggregate batch weights

for changes in their moisture content?Yes

No 2-A.6. BATCHING SYSTEMS

2-A.6.1. Definitions and Requirements of Component Individual Batcher Controls.

Batching controls are the part of the batching equipment that provides means for

operating the batching device for an individual material. They may bemechanical, hydraulic, pneumatic, electrical, etc. or a combination of thesemeans. A batching system is a combination of batching devices and batchingcontrols necessary for the accurate and consistent batching of concrete ingredients

in the desired proportions. Normally, a batching system would include batchingdevices and controls for cementitious materials, aggregates, water, and

admixtures.

2-A.6.1.1. Weigh Batcher Controls (Cementitious materials and aggregates must be

batched by weight; water and admixtures may be batched in a weigh batcher or byvolume)

Automatic Control – When actuated by a single starting signal, an automatic weigh-

batcher control shall start the weighing operation of cementitious materials, aggregate,water, or admixture, and stop the flow automatically when the designated weight has been reached. It shall be interlocked to assure that:

(a) The charging gate or valve cannot be opened until the scale hasreturned to zero balance within ±0.3% of the scale capacity;

Yes

No



21

(b) The charging gate or valve cannot be opened if the dischargemechanism is open;

Yes No

(c) The discharge mechanism cannot be actuated if the charging gate or

valve is open; andYes

No (d) The discharge mechanism cannot be actuated until the weight of material is within the tolerance specified in 2-A.5.1.

Yes No

2-A.6.2. System Requirements

2-A.6.2.1. Automatic System: A combination of the necessary individual weigh- batchers and volumetric batching devices (if water or admixture is measured

volumetrically in the plant), the controls of which are all automatic (in accordance with2-A.6.1.1) and meet the following automatic-system requirements:

(a) All batching equipment activated by a single starting mechanism, except that a

separate starting mechanism is permitted for volumetric batching of water and/or admixture not batched at the time of weighing the other ingredients.

Yes No

N.A. (b) The discharge of any weighed ingredient in the system may not start unless batching controls for all weigh batchers have been cleared of the previous batch,

with scales returning to zero tolerance, and until all weighed ingredients have been weighed within the required tolerances.

Yes No

N.A. (c) Volumetric admixture dispenser controls (if any) interlocked with volumetric

water batching controls or the controls of at least one weigh batcher to prevent thedischarge of both admixture and the interlocked ingredient(s) unless both theadmixture dispenser and the interlocked batching device(s) have been cleared of

the previous batch.Yes No

N.A.



22

2-A.7. Recorders:2-A.7.1. Devices that provide a permanent record of the quantity of cementitious

materials, aggregate, water or admixture measured into a particular batch of concrete.

Cementitious Aggregate Water Admixture

Graphical chart recorder provides indication of

material beingweighed/measured. Agraphical recorder shall

register scale readings within± 2 percent of total scalecapacity

Yes

No

Yes

No

Yes

No

Yes

No

OR

Digital recorder provides a printed record of material being weighed/measured. A

digital recorder shallreproduce the scale readingwithin ± 1 percent of scale

accuracy for cement,admixtures and water and ±

3% for aggregates

Yes No

Yes No

Yes No

Yes No

2-A.7.2 Recorders shall be:

Cementitious Aggregate Water Admixture

Properly protected, that is, provided with effective

security to prevent tampering

with records

Yes

No

Yes

No

Yes

No

Yes

No

Provide traceability of the

particular batch with thecorresponding delivery ticket.

Yes No

Yes No

Yes

No

Yes No

Register empty balance or tareto within 0.3% of scalecapacity for weighed

ingredients.

Yes No

Yes No

Yes No

Yes No

Register the quantity of

ingredients batched. Yes No

Yes No

Yes No

Yes No



23

2-B. OLD-GENERATION BATCHING AND MIXING CONTROL EQUIPMENTS

2B.1. SCALES 2-B.1.1. Each scale comprised of a suitable system of knife-edge mechanicallevers whichwill weigh consistently with loads indicated either by means of a full-reading dial or a

digital read-out or display. For all types of batching systems, either dial or digital display,is the batch operator able to read the load indicating devices from his normal station?

Yes No

2-B.1.2. Do analogue scales have increments not exceeding 5 kg each for cement and

mineral admixtures, 25 kg for aggregates and 2 kg for water? (Clause E-1 (b) of Annex Eof IS 49263)

Yes

No

2-B.1.3. Have the system of knife-edge mechanical levers been calibrated in increments

not exceeding 5 kg or less each for cement and mineral admixtures, 10 kg or less for aggregates and 2 kg or less for water? (Clause E-1 (c) of Annex E of IS 49263)

Yes No

2-B.1.4. Does the records show that at east 1000 kg of suitable calibrated and stampedtest weights have been used for checking accuracy of scales.

Yes No

2-B.1.5. Does a systematic recheck of scales carried out frequently (at least once every 2 months for mechanical/knife-edge system)? (Clause E-1 (j) of Annex E of IS 49263)

Yes No

2-B.1.6. Is prompt recalibration done and correction carried out if the plant is moved or non-compliance is indicated in the 2-month rechecking?

Yes No

2-B.1.7. Is a systematic record of calibration of weighing and measuring systemavailable?

Yes No

2-B.1.8. Are adequate permanent facilities provided for the application of test weights tothe weighing hopper or system? (Clause E-1 (j) of Annex E of IS 49263). [These facilities

may consist of anchor /suspension points, or trays, or platform, or hangers or other equipment as required.]

Yes

No



24

2-B.1.9. Are the personnel involved in the work of calibration of weighing equipmentscompetent and fully trained? (Clause E-1 (p) of Annex E of IS 49263)

Yes No

2-B.1.10 Beam-Indicating Scales

2-B.1.10.1 Have the beam-indicating scales been provided with zero balance beam,

balance indicator, and separate weighing beam for each ingredient of a batch to beweighed on the same scale?

Yes No

2-B.1.11. Dial-Indicating Scales 2-B.1.11.1. Is the dial head mechanism enclosed adequately so as to be dust tight?

Yes No

N.A

2-B.1.11.2 Does dials indicate load in batch continuously from zero balance to full

weighing capacity of the scale?Yes No

2-B.1.11.3. Are the dial-indicating scales equipped with a digital indicator and display

protected from dust with numbers large enough for good readability?Yes No N.A.

2-B.2. WEIGH BATCHERS (Clause 9.1.2 and 9.1.3 of IS 49263)

2-B.2.1. Have the hoppers for weighing cement, aggregates, and also water andadmixtures (if measured by weight) consist of suitable containers freely suspended from a

knife-edge mechanical lever/scale, and are they equipped with necessary charging anddischarging mechanisms?

Yes

No 2-B.2.2. Are the hoppers capable of receiving maximum rated load without contact of the

weighed material with the charging mechanism?Yes No



25

2-B.2.3. Is the hopper charging mechanism capable of stopping flow of material within batching tolerances specified in para 2-B.5.1 and preventing loss of material when

closed?Yes No

2-B.2.4. Is wind/weather protection sufficient to prevent interference with weighingaccuracy?

Yes No

2-B.3. BATCHING DEVICES FOR WATER

2-B.3.1. Water is measured by:

Volume Weight

2-B.3.2. Are water meters/weigh batchers equipped with a cut-off device capable of

stopping the flow within the tolerances specified in 2-B.5.1?Yes No

2-B.3.3. Is cutoff device free from leaks when closed?

Yes No

2-B.3.4. If measured volumetrically, are water meters equipped with a volume-setting

device capable of being set to increments at least as small as 5 litres or a register capableof being read to, 5 litres or both?

Yes No

2-B.3.5. Is the system capable of providing an indication, visible to the batch operator , of the volume/weight batched at any point in the metering/weighing operation?

Yes

No

Volumetric Tank Water Batchers:

2-B.3.6. Are tank water batchers equipped with necessary filling and discharge

valves that are leak-free when closed and is the fill valve capable of stopping flow withinthe tolerance specified in Section 2-B.5.1?

Yes

No

2-B.3.7. Is there a gauge or other device that clearly indicates to the batch operator the volume of water in the tank from the zero point to capacity of the batcher and whichcan be read to 5 litres?

Yes

No



26

2-B.3.8. Is the tank equipped with an overflow pipe at batcher capacity level if it is lessthan tank capacity?

Yes No

2.B.3.9. Is the tank water batcher equipped with a valve to remove overloads?

Yes

No

2-B.4. DISPENSERS FOR LIQUID ADMIXTURES (Clause 9.1.2 and 9.1.3 of IS

49263)

Chemical admixtures (either by weight or volume) shall be added to the concrete mixturewith the help of a dispenser — a device for batching of liquid admixtures. Admixtures

shall not be administered with manual method.

2-B.4.1. Liquid admixtures are measured by:

Volume Weight

2-B.4.2. Is there a separate dispenser for each liquid admixture in regular use?

Yes No

2-B.4.3. If more than one admixture is being used through a single dispenser withoutflushing of the dispenser with water after each cycle, do the plant personnel ascertain thatthe admixtures in actual use are compatible with each other and that the mixing of

admixtures prior to introduction in to the concrete is not detrimental?Yes No N.A.

2-B.4.4. When using a single dispenser, if the admixtures are not compatible with eachother, is the dispenser flushed with water after each cycle?

Yes

No

N.A. 2-B.4.5. Are the pipes carrying admixture free from leakage and are they properly valved

to prevent backflow or siphoning so as to ensure that the measured amount is discharged?Yes

No 2-B.4.6. Is each dispenser of liquid admixture provided with an accurately calibratedcontainer (if measured by volume) in which the admixture can be collected when it is

desired to check the accuracy of measurement as indicated in 2-B.5.1?Yes No

N.A. 2-B.4.7. Do the admixture dispensers have scale increments which enable materials to be batched within a tolerance of 3% of the scale reading?

Yes



27

No 2-B.4.8. Do dispensers of liquid admixtures provide visible indication of the quantity

batched or interlock cut-off when liquid admixture supply is not available to thedispenser? (This is to prevent dispensing air).

Yes

No N.A.

2-B.5. ACCURACY OF PLANT BATCHING (Clause E-1 of Annex E of IS 49263)

{Note: For weighed ingredients, accuracy of batching shall be determined by comparison

between the desired weight (as indicated by the batch operator and corrected for aggregate moisture, if required) and the actual scale reading. In case water and admixtureare added by volume, the accuracy of volumetric measurement shall be determined by

checking the discharged quantity either by weight on a scale or by volume in anaccurately calibrated container.}

2-B.5.1. The accuracy, sensitivity and arrangement of weighing devices shall be such asto enable the materials to be batched within the following tolerances:

Cement and mineral admixtures: Within ± 2 percent of the quantity of constituents being measured

Yes No

Aggregate, chemical admixture and water : Within ± 3 percent of the quantity of constituent being measured

Yes No -

2-B.5.2. Is there an appropriate system of finding aggregate moisture either manually or

automatically to provide aggregate of fairly consistent moisture content to the batcher andto detect changes of 1 percent in the moisture content of aggregate?

Yes

No

2-B.5.3. Are appropriate procedures followed for adjustment of aggregate batch weightsfor changes in their moisture content?

Yes No

2-B.6. BATCHING SYSTEMS

2-B.6.1. Definitions and Requirements of Component Individual Batcher Controls.

Batching controls are the part of the batching equipment that provides means for operating the batching device for an individual material. They may be

mechanical, hydraulic, pneumatic, electrical, etc. or a combination of these



28

means. A batching system is a combination of batching devices and batchingcontrols necessary for the accurate and consistent batching of concrete ingredients

in the desired proportions. Normally a batching system would include batchingdevices and controls for cementitious materials, aggregates, water, andadmixtures.

2-B.6.1.1. Weigh Batcher Controls (Cementitious materials and aggregates must be

batched by weight; water and admixtures may be batched in a weigh batcher or byvolume in a volumetric device.)

Automatic Control – When actuated by a single starting signal, an automatic weigh- batcher control shall start the weighing operation of cementitious materials, aggregate,water, or admixture, and stop the flow automatically when the designated weight has

been reached. It shall be interlocked to assure that:

(a) The charging gate or valve cannot be opened until the scale has

returned to zero balance within ±0.3% of the scale capacity;Yes

No (b) The charging gate or valve cannot be opened if the discharge

mechanism is open;Yes No

(c) The discharge mechanism cannot be actuated if the charging gate or

valve is open; andYes No

(d) The discharge mechanism cannot be actuated until the weight of material is within the tolerance specified in 2.B.5.1.

Yes No

2-B.6.1.2. Volumetric Batching Device Controls (This pertains to the controls usedfor measurement of admixtures in a volumetric admixture dispenser or the measurement

of water with a water meter or a volumetric batcher tank.)

Automatic Control – When actuated by a single starting signal, an automatic volumetric

control shall start the measuring operation and stop the flow automatically when thedesignated volume has been reached.

2-B.6.2. System Requirements

2-B.6.2.1. Automatic System: A combination of the necessary individual weigh-

batchers and volumetric batching devices (if water or admixture is measuredvolumetrically in the plant), the controls of which are all automatic (in accordance with2.6.1.1 and meet the following automatic-system requirements:



29

(a) All batching equipment activated by a single starting mechanism, except that aseparate starting mechanism is permitted for volumetric batching of water and/or

admixture not batched at the time of weighing the other ingredients.Yes No

N.A. (b) The discharge of any weighed ingredient in the system may not start unless

batching controls for all weigh batchers have been cleared of the previous batch,with scales returning to zero tolerance, and until all weighed ingredients have been weighed within the required tolerances.

Yes No N.A.

(c) Volumetric admixture dispenser controls (if any) interlocked with volumetricwater batching controls or the controls of at least one weigh batcher to prevent thedischarge of both admixture and the interlocked ingredient(s) unless both the

admixture dispenser and the interlocked batching device(s) have been cleared of the previous batch.

Yes No

N.A.



31

4. TICKETING SYSTEM (As per Annex G of IS 4926)3

The Delivery Ticket should contain the following information

1 Name of the ready mixed concrete Company Yes

No

2 Plant designation if Company operates more than one plant Yes No

3 Serial No. of ticket Yes No

3 Delivery date Yes

No

4 Truck No. Yes No

5 Name of the Purchaser Yes No

6 Name& location of the site Yes No

7 Grade of concrete or mix description of the concrete Yes No

8 Specified target workability Yes No

9 Minimum cement content ( if specified) Yes No

10 Type of cement and grade ( if specified) Yes No

11 Maximum free water-cement ratio ( if specified) Yes No

12 Nominal maximum size of aggregate Yes

No

13 Generic type or name of chemical admixtures included Yes

No

14 Generic type or name of mineral admixtures included Yes

No 14 Quantity of concrete in m3 Yes

No

15 Time of loading Yes No

16 Signature of authorized person Yes No

17 A statement warning the purchaser of the precautions neededto be taken when working with cement and wet concrete.

Yes No



32

On site information

1 Time of arrival at site Yes No

2 Time when discharge was completed Yes No

3 Any water/ admixture added by the supplier to meet the

specified workability

Yes

No 4 Any extra water/ admixture added at request of the purchaser

of the concrete, or his representative and his signature.

Yes

No

5 Pour location (if informed by client) Yes

No

6 Signature of the purchaser or his representative confirming

discharge of the load

Yes

No



33

5. DELIVERY FLEET INSPECTION

It is the responsibility of RMC producer to ensure that each truck mixer is inspected toconfirm compliance with various requirements given in this section. The RMC facility

will maintain a register of such inspection, which would be made available to the third- party auditor. The auditor is free to choose any one or more truck mixers from register for his audit. It is recommended that the RMC facility may maintain the register in the format

included in section 5.8. It is suggested that the auditor should audit around 10% of thetruck mixers from the register. Certification will be granted only if all the audited truck mixers are found acceptable as per criteria listed in this section.

5.1. Hardened concrete built up in mixer drum and on blades Are the truck mixers maintained in an efficient and clean condition? Is there an

appreciable accumulation of hardened concrete in the mixer drum and on the mixer blades?

Yes

No

5.2. Mixer Blade wears

The wear of mixer blade shall be checked at the point of maximum drum diameter nearest to the drum head. The blade is considered excessively worn if height of the blade

at this point, measured from the drum shell, is less than 2/3rd of the original radial height.Are the blades free of excessive wear?

Yes No

5.3. Charging hopper

5.3.1. Is the surface of charging hopper clean and smooth?Yes

No

5.3.2. Is the charging hopper free from appreciable accumulation of concrete?

Yes No

5.4. Discharging opening, hopper and chute

5.4.1. Is the surface of discharging opening, hopper and chute clean and smooth?

Yes No

5.4.2. Are the discharging opening, hopper and chute free from appreciable accumulationof concrete?

Yes No

5.5. Speed of agitation

The recommended operating speed for agitation (in rpm) shall be as per the

recommendation of the manufacturer. The speed of the drum should generally be in the



34

range of 4 rpm to 14 rpm. Minimum and maximum operating speed shall be visuallyverified. Is the agitating mixer capable of operating at mixing speed in the range of 4 to

14 rpm?Yes No

5. 6. Water tank, meter and pump system

5.6.1. Is the gauge/meter on water tank fitted to the truck mixer clean and legibly

graduated?Yes No

5.6.2. Is the water pump / injection system in good working condition?Yes

No

5.6.3. Is there any leakage of water from the nozzle into the mixer?Yes

No

5.6.4. Check on calibration of water meter does not show variation beyond 2%?Yes

No N.A.

5.7. General

5.7.1 Are all documents of truck mixer (registration book, insurance receipt, etc) as per

statutory requirements?Yes

No

5.7.2. Is first aid box provided in the cabin of truck mixer?Yes

No



35

5.8. Inspection record of Truck Mixers

Company: City:

Truck No.__________________ Rated Capacity: ______________________

Name of manufacturer and make:_____________________________________________ Date of previous inspection: ________________________________________________

Date of current inspection: __________________________________________________

5.9. Inspection record of Truck Mixers: (For the use of RMC producer)

(Each truck mixer’s inspection to be entered in a separate table)

Items in Check List Compliance

5.1 Yes/ No

5.2 Yes/ No

5.3.1 Yes/ No

5.3.2 Yes/ No

5.4.1 Yes/ No

5.4.2 Yes/ No

5.5 Yes/ No

5.6.1 Yes/ No 5.6.2 Yes/ No

5.6.3 Yes/ No

5.6.4 Yes/ No

5.7.1 Yes/ No

5.7.2 Yes/ No

5.9 Summery of Inspection Record of Truck Mixer (For the Use of Auditor)

Truck No.

Date of previous

inspection by

producer

Name of Manufacturer

and make

RatedCapacity

Date of Inspection

Compliance

Yes / No

Yes / No

Yes / No

Yes / No

Yes / No

Yes / No

Yes / No

Yes / No

Total no. of truck mixers available for use:Total number of trucks inspected by producer ____________

No. of truck mixers checked and found acceptable:



36

6. LABORATORY

6.1. General

6.1.1. Does the RMC production facility have an attached testing laboratory?Yes No

6.1.2. If no, where does the routine testing been carried out?Central lab of Company Third-party lab

N.A. 6.1.3. Has the central lab of Company or third-party lab been audited recently?

Yes No N.A.

( Note: If the RMC facility does not have in-house testing laboratory and the testing iscarried out in the central lab of Company, it is essential to ensure that the central lab isaudited and that the validity of the audit has not expired)

6.1.4. If the answer to question 6.1.3 is ‘yes’, mention the name of auditor, date of

certification and its validity. Name of Auditor

Date of certification Validity of certification

N.A.

6.2. Test facilities

6.2.1. Plant laboratory/central laboratory/third-party laboratory has facilities to carry outthe following test:

Cement Standard consistency (conforming to IS)10

Initial and final setting time (conforming to IS) 10

Compressive strength (conforming to IS)

10

Aggregates Sampling (conforming to IS 2430)

5

Moisture content (conforming to IS 2386-PartIII)6

Silt content

Bulk density

Sieve analysis (conforming to IS 2386-Part-I)7

Water pH

Chlorides

Sulphates

Admixture Specific gravity

Concrete Slump (conforming to IS 1199)8

Unit weight (conforming to IS 1199)8

Strength (conforming to IS 516)9



37

6.2.2. Are the equipments used for different tests mentioned in 6.2.1 in conformity with

the requirements specified in different codes?Yes No

6.2.3. If the answer to the question in 6.2.2 is ‘No’, mention the major shortcomings intests (add separate sheet, if necessary)

6.2.4. Are the tools and equipment used for carrying various tests mentioned in 6.2.1maintained in neat and clean condition?

Yes No

6.2.4. Are the measuring and testing equipments (weighing balance, weights, sieves,

proving ring of compression testing machine, etc.) calibrated regularly?Yes

No 6.2.5. Mention the frequency of calibration and the date till which current calibration can be considered valid for each of the following apparatus:

Frequency Validity

Weighing balance

Weights

Proving ring

Measure for unit weight

6.2.6. Is a proper record of calibration kept in the laboratory?Yes No

6.2.7. Are the dimensions of cube and beam moulds within the code-specified tolerancesafter repeated use?

Yes No

6.2.8. Does the curing tank have the facility of maintaining temperature of curing water at27 ± 2 0C?

Yes No

6.2.9. Type of mixer used in laboratory

Tilting drum Pan-type Other (describe)



38

6.9.10. Is the laboratory mixer kept in clean condition?Yes

No 6.2.10. Is there appreciable built-up of materials on mixer blades or inside face of mixer?

Yes

No

6.3. Testing procedures6.3.1. Are the minimum testing frequencies specified in IS 49263 and other relevant codesfollowed for the conduct of tests mentioned in 6.2.1?

Yes No

6.3.2. Are well documented test procedures available in the laboratory?

Yes No

6.3.3. Are the well-documented test procedures displayed in laboratory for the guidance

of operators/supervisors?Yes No

6.3.4. Are the test procedures given in relevant codes or equipment manufacturer’s

manual followed meticulously in day-to-day practice?Yes No

( Note: This can be ensured by witnessing some of the tests being carried out in the lab

and/or by asking relevant questions to the operators/supervisors).

6.3.5. Are original or certified copies of relevant codes available in the laboratory?Yes No

6.4. Personnel

6.4.1 Are lab technicians adequately trained and qualified to carry out day-to-day routine

testing on ingredients and concrete?Yes

No 6.4.2. If yes, record the details of in-house and external training undergone by thetechnicians during the past one year in the following format.(use separate sheet if needed)

Name of technician Training topic Date of training Agency name

6.4.3. Are the duties and responsibilities of lab technicians clearly defined and welldocumented?

Yes

No



39

Bureau of Indian Standards referred in Checklist

1. Plain and Reinforced Concrete- Code of Practice ( Third Revision) IS 456 : 2000( Reaffirmed 2005), p. 100.

2. Concrete Admixtures- Specifications (First Revision),IS 9103:1999 ( Reaffirmed

2004), p.14.3. Ready-Mixed Concrete- Code of Practice (Second Revision), IS 4926: 2003, p.

18.4. Methods for Testing Performance of Batch-type Concrete Mixers ( First Revision)

IS 4634: 1991(Reaffirmed 2005), p.3.

5. Methods for Sampling of Aggregates for Concrete ( First Revision) IS 2430 :1986 ( Reaffirmed 2005), p.12.

6. Methods for Test for Aggregates for Concrete Part 3 : Specific Gravity , Density,

Voids, Absorption and Bulking. IS 2386 Part 3 : 1963 ( Reaffirmed 2007 ), p. 177. Methods of Test for Aggregates for Concrete Part 1: Particle Size and Shape. IS

2386 :Part 1:1963 ( Reaffirmed 2007), p. 188. Methods of Sampling and Analysis of Concrete. IS 1199 : 1959( Reaffirmed

2004), p.44.

9. Method of Test for Strength of Concrete. IS 516: 1959 (Reaffirmed 2004), p. 24.10. Specification for 53 Grade Ordinary Portland Cement. IS 12269 :1987

(Reaffirmed2004), p 11



40

Notes

check list for audit

Documents